2004 Ford Expedition XLT (rear) AC cl...
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Rocklin, CA

#21 Jul 8, 2012
As per Jose from Hollywood FL's post above, I had the same problem and his advice helped me fix it:

"The problem you are encountering is a faulty A/C actuator. When you open the rear tail gate, on the right (passenger) side plastic molding there is an access compartment you can get to by popping the top lid (long, looks like a tray). Inside you will have access to the rear A/C unit. There are 2 white electrical cases. One you can easily see and access, and the other is on the left hand side of the A/C unit."

In my case, I simply unplugged the cable assembly going into the far left hand rear AC unit activator, and the metronnomic "click click click" stopped. The downside is that now the rear air only blows from the roof vents, but those can be pointed away or closed by any rear passenger.

Thanks, Jose!

Chester, VA

#22 Aug 5, 2012
Thanks for all the tips. They saved me time and money. We were going to try taking other things apart first. Is it safe to leave the actuator unplugged? Thanks in advance.

Gulfport, MS

#23 Apr 22, 2013
I have an 06 expedition. I have the same sound but it is coming from what I believe to be an actuator. but mine is located in the front of the vehicle just behind the radio and a little to the right. It is a white square box. I unplugged the harness coming into it and it stopped the clicking noise. anyways i am hearing a lot in this forum about actuators located near the rear of the vehicle , but not anything about the front actuator. Can any one help?

Fort Lauderdale, FL

#24 Aug 15, 2013
I know I'm a lil late but I read someone saying there air only blows out of the defrost... Look under your hood on the left side there is a small vacum line coming from the fire wall look for a very small crack or it could just be broken..you have to look very good. Might even be slightly dry rotted.good luck hope this helps.

United States

#25 Mar 16, 2015
Jose wrote:
The problem you are encountering is a faulty A/C actuator. When you open the rear tail gate, on the right side plastic molding there is an access compartment you can get to by popping the top lid (long, looks like a tray). Inside you will have access to therear A/C unit. There are 2 white electrical cases. One you can easily see and access, and the other on the left hand side of the A/C unit. First check the easy access case by unplugging the electric casing. Turn the AC back on. If no more noise, then this is the faulty actuator. It comes of with three screws and you can purchase at a local auto part store. This actuator is the one that allows you to switch from hot to cold settings. If you unplug this one and the noise persists, you have a bigger problem. The faulty actuator on the left hand side of the AC unit is much harder to replace. You will need to remove the rear paneling to access (unless you have really, really small hands). This actuator is the one that controls the top vents versus the floor vents for the rear AC.
That's backward the easy one opens top or bottom vents

Riverside, CA

#26 Apr 20, 2015
I get the same clicking sound on my 2004 Expedition but the AC is not even on, it does it as soon as I turn the car ON and it won't stop until I turn the car off, any suggestions what it might be?

Shelton, WA

#27 Oct 27, 2015
I am looking to purchase an 04 with this issue, can anyone who has worked this problem tell me is it possible to just remove the motor, and live with air con just coming from the front of the vehicle? I live in the Pacific NW, and while air con is nice 2 months out of the year, it is not crucial.

Fort Lauderdale, FL

#28 May 27, 2017
My 2004 expedition started with clicking noise then last month while driving it made a loud grinding noise followed by a smell,of some type of fluid, don't know what it was smelling. Since this the air blows out hot air. Any suggestions on what the loud grinding noise would have been. I never messed with fixing an ac unit on car and don't know to even start to look. I'm pretty good at following YouTube videos but I need a starting potential diagnosis first. Any help is appreciated

Newport, KY

#29 Jul 1, 2017
Luke wrote:
<quoted text>

Jose, very well stated. I just followed your instructions and replaced
my rear actuator in my 04 Expedition. I paid $57 for the new one. Sadly,
after inspecting the internals, I see a plastic gear has lost some teeth,
which causes the click. This gear is marked with a 7, with the larger
one marked with a 5. An internal picture (of something similar) is here:


Also, one important tip from:


One last thing...

Before you begin. Turn your HVAC control to either full cold or full hot. Remember which. You'll need to set the position of the new actuator before you insert it. You can't move the actuator manually.


I simply plugged in the new actuator prior to installing it, and then
turned on the rear climate control. It moved the actuator in place for
easy installation.

Ultimately, looking at the internals of it, I'd rather repair than replace. Compared with the electronics of the thing, we're probably
looking at a 5 cent part.

If anyone can post a link to actuator gears, you'd save every Ford owner
who is willing to work on a car fifty bucks.

United States

#30 Aug 19, 2017
CAROL wrote:
03 FORD EXPEDITION blows the AC air by the defrost section in the front out of the dash board. minimum cold air is blowing out of the front or the foot area even if i put it to the high. I was told I need a climate control panel that controls the entire AC.$600.00
You most likely just need a new switch. Very cheap or go get one from your local cash and cart what or junkyard depending what part of the state's your from

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