Hi,
If you are hearing a clicking sound, my first thought would be the mode door actuator is failing. The mode door, also known as an air door actuator, is responsible for airflow direction.
The clicking you are hearing is likely a plastic gear on the actuator that has a few broken teeth and can't hold a specific position.
Here is what I suggest. Remove the actuator and then see if it responds when you change the airflow direction by placing a small amount of resistance on it with your hands. See if that is where the clicking is coming from. If it is, replace it.
If you look below, I attached a pic showing the actuator's position. Two screws hold it in place. It is a bit tough to remove it, but it can be done. If you want, place your hand on the actuator to see if you can feel the clicking prior to removal.
Let me know what you find or if you have questions.
Take care,
Joe
See pics below.
Image (Click to make bigger)
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Tuesday, August 2nd, 2022 AT 9:40 PM