Working on brother-in-laws 2009 F150, only hot air on passenger side-no cooling even when control turn to max cool (60). Clicking noise heard when starting truck. Ordered new blend door actuator for passenger side, replaced, pulled fuse, waited, reinstalled fuse, turn key on (not starting truck) for 30 seconds. Seemed to go through calibration and started truck-now have cooling. Next day he tells me he still had clicking sound when starting truck, but still had cooling. Two weeks later, now he says it is back to all heat-no cool on passenger side. Now wondering if there is a control board/wiring issue. Opened old actuator, looked good inside-no broken gears, but did not test motor. This is a dual heat auto control system. Thoughts-ideas??

 

I wouldn't rule out the actuator or motor. I would thoroughly test it.

 

I just replaced the acuator. Should last longer than a week or two!

 

My best suggestion is to remove the blend door assembly and test it while it is out a couple times. Maybe even keep it out and drive around to see if while driving it does anything funky sitting on the floor.

If it is a control board issue, it will start to act flaky. If that is the case, it might a bad solder joint or something else going on the board.

 

"remove the blend door assembly" - it was an SOB just to replace the acuator. To remove the whole assembly would be tearing out half the dash?

 

Yes, unless someone on here knows of a better way.