Question about 2003 Ford Expedition

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Clicking noise behind right side second row seat

When I select roof or floor heat/air vents there is a clicking noise and a slight electrical burning smell, I keep it on floor now and there isn't a problem but when I switch it to roof vents is when I hear and smell it, any ideas??

Bob I have the same problem on my 2003 Ford Expedition Eddie Bauer. How do yo uget the plastic grill in the back (behind the 3rd seat) off to get to the Rear Temp Blend Motor?

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  • bsmueller Jan 28, 2009

    We had the same problem. It clicks when one. It has been to the ford dealership and examined. They told us that it would be a hefty bill to determine the cause. Right now, we just had them disconnect the power to the rear air :O( Let me know if you find a better solution.



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I had the same problem. There are two regulators and the one that determines air direction is broken. The door inside is hung up and it strips the gears in the regulator. You can leave all the seats in the car but you have to remove several panels on the inside to get to the regulator. Many or them pry off. This can be risky if you are not careful and you may decide you don't want to risk it. Others need bolts removed (around the seatbelts) to remove. If you get to that point you will find two regulators that are white in color. They are anchored by 4 screws (i think) and come right out. Determine you have the proper one by toggling the face/floor button. You can follow the noise. The real problem here is with the door that hangs up. Mine hung up because the whole assembly was anchored against a big wiring harness on the back side that cracked the whole casing. Bad engineering. You may have to remove some sharp cracked pieces so the door moves easily. Problem is that you now will have a hole in your AC/Heating unit. You can replace that as well (expensive) or seal it some other way. By the new regulator from Ford and reassemble and you're done. If you are handy it should take you a couple of hours. My bro had the same problem on his Explorer and we fixed it much quicker the second time around. If you are not handy, you might want to reconsider.

Posted on Feb 01, 2009

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The easiest way to replace the actuator for the aux. temp control is to loosen up th right side panel in front of it. Put the seats down to make it easier.

Posted on Jan 26, 2009

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Do you have children? Sounds like to me that the kids (or others???) have possibly dropped something down into the rear vents and hung up the output air direction door (We are talking about the ones in the back of the vehicle - Not the front dashboard -, correct?) If it is the front, I think sometimes they can come out of adjustment and hang up (or just plain malfunction) - they will do the same thing described below...I'm not sure how to access these, the Ford man could better tell you - because I can't see them. Sometimes they are located in the evaporator box or very colse by, and with others, the entire panel will have to come off in order to access them. Sometimes (alot of times) the seats have to come out as well...(If like the ones' in the vans, they are located to the immediate left side of the intermediate (second row) seats. oh boy!!! of joy!!! -Actually it's not too bad at ll.. just time consuming if you don't have a garage and compressed air / air tools. The Engineers that design these things hide them very deeply on purpose so that dealership intervention is almost always definitely required. There are probably little tabs (Only sometimes done this way) that can be depressed to sneak the vents out, but knowing where exactally they are is one of those things that only dealership secrets can accurately define. DO NOT PRY ON THEM!!! They are very brittle - especially when exposed to high heat, time, and other ambient air temperatures (cold). Sometimes, these things are also screwed in from the rear, regardless. Help any? If there is an electrical short, the fuse will ususally blow in order to protect the circuit and the wiring, and keep there from being any fires. The worst case scenario involves the expensive control unit being damaged due to this "short", so I'd recommend keeping it where it works best (floor?) and not attempting to move it until it is fixed, otherewise you may have to replace the control unit as well, and that is no joyride ($$$)... It is rare that door mixture actuators cause any kind of "smell" or "odor" at all - they usually work, or don't work - they are permanenet magnet motors and do not use windings that cause smell when shorted. - I would tend to think that maybe there is another problem that either corresponds to the switch being pressed, or it is just palin old coincidince...I've seen some really strange one's...sorry I couldn't help more - maybe you can find a Ford tech here that can help you more...

Posted on Jan 26, 2009

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