There is a factory TSB concerning your problem.
Here it is.
A/C - Noise From Front Of Passenger Compartment
TSB 06-6-10
04/03/06
NOISE IN RIGHT FRONT OF PASSENGER
COMPARTMENT/AIR INLET DOOR ACTUATOR
INOPERATIVE/BLOWER MOTOR FAN NOISE
FORD:
2005-2006 Five Hundred, Freestyle
MERCURY:
2005-2006 Montego
ISSUE
Some 2005-2006 Freestyle/Five Hundred/Montego vehicles may exhibit noise coming from the right front passenger compartment and/or air inlet (recirculation) door actuator inoperative.
ACTION
Refer to the following Service Procedure to isolate the noise concern.
SERVICE PROCEDURE
1. If the noise is coming from actuator motor when max A/C or recirculation is selected, or door will not move, remove actuator, and verify door moves freely and does not bind.
A. If the door moves freely, replace the actuator with revised part following Workshop Manual, Section 412-01.
B. If the door does not move freely follow normal diagnostics.
NOTE DO NOT RUN ACTUATOR MOTOR WHEN IT IS NOT CONNECTED TO AIR PLENUM.
2. If the noise is coming from the blower motor area and changes with blower speed, remove and inspect blower fan wheel for cracks near shaft. Replace the wheel if cracked.
3. For all other concerns refer to normal diagnostics.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
060610A 2005-2006 Five Hundred, 0.3 Hr.
Freestyle, Montego:
Replace The Air Inlet
Actuator (Do Not Use With
19616A, 19700D,
19700D4, 19805A)
060610B 2005-2006 Five Hundred, 0.4 Hr.
Freestyle, Montego:
Replace The Blower Fan
Wheel (Do Not Use With
19616A, 19700D,
1 9700D4, 19805A)
060610C 2005-2006 Five Hundred, 0.5 Hr.
Freestyle, Montego:
Replace The Air Inlet
Actuator And The Blower
Fan Wheel (Do Not Use
With 19616A, 19700D,
19700D4, 19805A)
DEALER CODING
CONDITION
BASIC PART NO. CODE
18504 (USE WITH OPERATION B) 01
19E616 (USE WITH OPERATION A
Saturday, December 3rd, 2011 AT 11:06 AM
