I am getting a periodic clunking noise that seems to come from the front right side of the cabin. First thought it was an outside noise, but it really seems to be coming from "behind" the glove box. The noise is real, seems like it goes away if I turn the HVAC system off, but it happens quite often when I'm driving, or even when I come to a stop at a light.

After reading the TSB's I'm even more sure this is my issue, but I don't read anything about noises. Can't say there is any heating issue, just the noises. Am I on the right track?

 

right behind your glove box is the recirc door (door that selects outside or cabin air).

Push the recirc button and listen to see if you hear a clunk.

 

I don't seem to get any noise when hitting the recirc button, just odd clunks at different times from the passenger footwell area. First thought was brake pad sticking, but had the calipers checked when I had the tires rotated, and the noise really seems to be coming from "inside" the dash area.

 

Finally someone with the same problem as me!

My clunks when accelrating from a light and my cold air goes away for a split second then comes back.

I already have the blend door replaced and that didnt help.

 

hmm, another thing I would check is the blower fan/motor assembly. I have a clunk in my truck when the recirc is pushed, so I'm going to drop the blower motor and see if I can access the recirc door to put some felt in there to quiet it up.

However, it might be worth your while to look there as well. The blower fan is also located right under the passenger side dash. You say it happens when the HVAC is on, maybe the motor or fan is making noise??

It might be worth dropping the blower and looking.

 

I have a clicking noise in the dash that came once the truck had about 10,000 miles. The only way to quiet it is to rotate the temperature control to full heat, or full cool. After reading the many posts about blend door problems, I am certain that is what is wrong with mine.

 

not to hijack but...i have the clicking AND a metallic squeak

i know the blend door is the clicking but what about the squeak?

 

I dont think there is any problem, my AC was blowin 29F this morning on my way to work. It only does it in stop and go traffic.

 

Mine did the same thing. I took it to the dealership and they replaced an actuator in the dash and that solved the problem. Now it controls the temp. real good.

 

Can you post a copy of what your dealer did? I am thinking I have had done what you got done and mine still has the clunk.

 

The blend door actuator motor was replaced and now the temp is easily controlled. Also, there is no more "elctronic growling/gurgle" noise coming from behind the dash.

 

was it the temp blend door or recirc blend door. there are several blends doors.

 

When I get back home, I'll check the paperwork more closely. Most likely it was the temperature blend door but I'm not sure.

 

Ya I have already replaced the temp blend door with a updated Ford part and that didnt correct the clunking noise. I am just learned to live with it, the truck is fine otherwise.

 

I took my truck into the dealer and asked about the grinding noise on the blend door referring to the TSB. They SA told me that the job would require taking off the entire dash to do the replacement... 8 hours out-of-warranty minimum. I took his word for it, figured it was just a noise and told him to hold off.

I just checked AllData... and it says it's a 1 hour repair to lubricate. WTF?!

Meanwhile, today while the HVAC was on AUTO w/ A/C enabled, it was blowing hot air (while idling), so I think the actuator may need to be replaced (it got cold when I started driving, so it may not be stuck, just no cold air cause I'm idling?). If I need to replace the actuator per the second TSB, they are going to quote me 8 hours again... but again, doing this work is 1 hour per AllData.

Anyone have any experience with this? Is this something I could do myself w/ the right parts / lubricant?