So I recently fixed the blend door motor on my 98 and was enjoying the AC. This morning I started it up and with the AC off I have what I would decribe as a rattling popping sound from the clutch area. If I turn on the AC the noise goes away. Do I need a whole clutch or is the bearing blown do to the AC not being used in god only knows how long?

 

You probably only need the clutch plate. Buy it from Ford (MotorCraft brand).