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I have this noise to. As far as I'm aware there is no TSB for this. This is on my list of "to do" things but it has fallen back just because the recirc still works and I can live with it, I have more pressing issues with the truck right now......... What I think the issue is is that foam on the door has fallen off, just like what happened to my mode door I fixed a month ago.
Anyway, I plan to drop the fan blower assembly, because I believe that you can reach the recirc door from this area. Then I wanted to take some felt and line the area where the recirc flap closes. I am going to use the felt side of industrial strength velcro.
If you get to this before me, let me know how it goes! Good luck.
Brian
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