Sheesh... This 03 Expy is starting to act like a used Chevy... First the Grinding from the rear end or wheel bearing (being fixed by dealer), then the 2nd day we had it the driver window wouldnt roll up and scratched the heck out of the tint (dealer fixed the window, not the tint... yet...) How hard is tint to repair or remove and redo?? Expensive??

and NOW the rear air motor (or something under the passenger side rear AC area is clicking when the rear air is turned on. It makes one clicking noise on the upper vents then a different clicking noise when the leg vent is turned on... It goes away when the rear air is turned off... Still blows cold air... Sound comes from under the panel above the rear passenger tire well... Any ideas??

I just wanna cut ties from this dealer and never do biz with them again... We live an hour from the dealer and we are tired of the hassle... So far the powertrain has been flawless... We thought we got a great deal on a one owner clean carfax and autocheck... The money we saved on negotiating the price is about gone...

Any help appreciated...

 

I replaced the part on my wifes 2004 over a year ago. The part that is clicking is the gear drive for the vent/floor selector (if I remember correctly). This part is very easy to replace if you have worked on cars before. If you do it yourself the part is roughly $90-$100 (if I remember correctly). Or it is over $300 to have ford do it.

 

It's the rear blend door motor. There are 2 of those in the rear, one for temperate adjustment, and another for floor/roof vent selection. On mine, the latter broke. Basically, what it is one of the gears inside the little motor looses a tooth, so the door keeps on skipping. It seems it's a common problem with these trucks.

I posted instructions on how to remove the rear panel here. Look at post 22 for the instructions and some pictures. Should take maybe 1-2 hours for the whole thing.

Also, as you can see in post 23, if you go to the junkyard, you can pick up the gears from older Expys and Navis. Just reach for the motors, and pop them open. That way you don't have to buy the whole motor.

Hope this helps. If you need further help, ask