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Re: a/c heating unit- blower works with no ac or heat
You did not say if this is a standard htr/ac or automatic temp control. Sounds like the temperature motor is failing ( automatic Temp Control) You can get to this through the glove compartment, though it is hard. The motor sits on top the plenum (4 8mm screws). remove and replace. You will need to break the case to remove one of the screws. It will not hurt anything just be sure to break small pieces ,just enough to remove the screws.
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there is a blower relay circuit board located right by the blower motor which sounds like your problem to me i've worked on several that had the same type problem and thats what it was. the two blower motor wires will plug into it and there are two screws that hold it on
I'm assuming the problem is the blower motor isn't coming on or working. 1st, check the fuse. 2nd, remove the glove box or pull the 2 tabs that act like stops when it's open ( the glove box will open out further) and you'll see the power plug connector for the blower unit. Turn on the blower through the climate control (heat, A/C, or whatever) and wiggle the connector to see if the blower turns on. If starts working, then an easy solution is pull the connector off and gently press the prongs together or inward. Then carefully reconnect with damaging the prongs. This worked for 96 Mark VIII due to the fact the prongs were not "seating" correctly in the female connector. It's been about 2 years since I did this and the connection is still good. If wiggling the plug doesn't work, pull the plug, turn on the climate control (heat, A/C), and check for voltage to the plug. That's about all I can help with.
I have the 03 Expy with continuous rear air unit "clicking" or more accurately flapping of the air damper while the plastic gears in the 2L2H-19E616-AA grind away into toothlessness. Ford designed this unit to find the end of travel by jamming the motor to a stop and monitoring the current to determine when to stop applying voltage. That would probably be fine if the gears were designed to handle the jammed torque or the motor did not slip out of groove and continue turning and cracking the plastic gears.
There are two white colored boxes, one is for the temp plenum door, the other the upper/lower air flow. To be sure, do what I did, turn on the ignition, rear ac/heat and listen for the obnoxious click/thump as you move the temp control from full heat to full cool, you will know which part. Disconnect the electrical connector, four bolts and it is out!
Go to your dealer, part should be about $60 or less, look on line, lots of dealers sell for this or less on internet.
Sounds like a problem with the front blower motor. there is a blower motor resistor for the front blower motor that controls the speed of the blower and tends to go bad or fry out the blower motor. thats the most likely scenerio since you stated the control head was lighting up and responded to button changes.