Question about 2004 Ford Expedition

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Rear A/C and heating unit makes a knocking sound when turned on

My 2004 Eddie Bauer Expedition is equipped with rear A/C and heating control. When I turn it on there is a distinct knocking sound from the rear unit. The control switch allows you to select either driver or rear passenger control of the unit settings. When the 'rear' posititon is selected on the overhead control the knocking is intermittent and last for a few minutes then stops. When in the '2', '3', etc. position is selected it is more prevelant and continues for several minutes before it becomes lighter or stops. The A/C and heat both work wonderfully, but the noise is aggravating as heck. Is there something I'm missing? Does the unit require periodic preventive maintenance checks and services? Please help me troubleshoot this problem.

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  • e7castillo Dec 07, 2008

    The unit is in an awkward spot, so I'll get some help removing it and get back to you. Thanks.

  • Anonymous Dec 17, 2008

    I just bought a 2004 Expedition recently that has the same sound. I found out on another site that it's a stripped gear on the flapper motor that operates the blend door. It causes the door to continually close and open. The replacement part costs about $325. from the dealer and is easy to replace I understand, once you get the cover parts off.
    Rob


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I had the same issue on my 04 Expedition. Like the other posting it is most likely the actuator motor that sets on top of the rear AC unit in the back. However it cost me about $35 dollars and about 15 minutes for me to replace. It is easy to access by removing the top cover that is located on the passenger side rear cover found in the very back underneath the rear glass. Also remove the cup holder which can be removed by prying upward until it pops loose.
The actuator is white and located on top near the front of the rear AC unit and is held in place by three screws. Simply remove the screws unplug connection. To reinstall the new one you may have to turn on the rear AC and barely plug in the actuator until is moves to the position so that it lines up with the blend door. When lined up the actuator should fit right back in place. You could also compare the old unit with the new one and make sure the shaft is in the same position so that you know it will fit back into place. If the new unit does not move when you plug it in to align the shaft, simply select floor or roof position (which is the opposite position you are currently in) on the rear AC control. This should activate the actuator and you can see the the shaft slowly move.

This fixed mine. It is a common problem and my local dealership had them on the shelf. More often they see the front AC unit have this problem but does occur on the rear unit.

Posted on Jan 02, 2009

  • ram03perez Mar 14, 2012

    Well I'm haveig the same problem but I have a 2003 f.250 diesel, and the sound is coming from passenger side. Is it the actuator?

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I have 2004 expedition Eddie Bauer with the same issue in the rear AC unit, following the advice above I found the problem, but it wasn't the top actuator. There's another actuator on the side of the AC unit as well as the top. Once you remove the top cover from the rear passenger side, you will see the actuator sits on the side of the of the AC unit, this one has 4 screws instead of 3 and is slightly tricky to remove since it is sideways. So be careful not to drop the screws when taking them off. Found the replacement part at AutoZone for $44 with lifetime warranty.

Posted on Oct 24, 2012

  • Topo Yiyo
    Topo Yiyo Oct 24, 2012

    i have 2004 expedition Eddie Bauer with the same issue in the rear AC unit, following the advice above I found the problem, but it wasn't the top actuator. There's another actuator on the side of the AC unit as well as the top. Once you remove the top cover from the rear passenger side, you will see the actuator sits on the side of the of the AC unit, this one has 4 screws instead of 3 and is slightly tricky to remove since it is sideways. So be careful not to drop the screws when taking them off. Found the replacement part at AutoZone for $44 with lifetime warranty.

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  • 194 Answers

This is the rear blower motor barrings the blower moter needs to be replaced

Posted on Dec 05, 2008

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