2001 Ford Windstar clicking noise

GRANTMAGER

MEMBER
2001 FORD WINDSTAR
6 CYL
2WD
AUTOMATIC
74,000 MILES

I am hearing a periodic clicking noise that sounds like it is coming from behind the lower part of the center dash (near the floor). This sound occurs whenever the key is truned to ign (engine does not have to be on). Clicking sound changes pitch when the AC temperature selector is moved from hot to cold and vice-versa. AC does not have to be on for the sound to occur. AC only blows cold air now even when the engine is hot - in fact it appears to be blowing straight outside air. I suspect some kind of air duct diverter is jammed. What do you think, and is it something that I can repair? Thanks.

1 Reply

DAVE H

MECHANIC
13,383 POSTS

OPERATION
MAIN A/C-HEATER SYSTEM
System airflow is controlled by a 6-port vacuum selector valve, an integral part of control panel. System air temperature is manually controlled by temperature control switch, which controls electric-actuated temperature blend-air door.
Blower motor electrical circuit uses ground side switching with blower switch and resistor assembly on ground side of motor, not battery side. This protects resistor assembly from overheating in event of an electrical short.
During system operation, with climate control switch in any setting except off and MAX A/C positions, blower motor draws in air directly into system through cowl air intake. In MAX A/C position, air flows from inside vehicle through recirculation duct. Once in system, air is blower driven through evaporator core and, depending on setting of temperature control switch, through and/or around heater core and into plenum. Air is directed from plenum to defrost nozzles, floor and instrument panel registers, depending on position of climate control switch.

VACUUM CONTROL MOTORS
Removal & Installation (Air Damper Door)
Disconnect vacuum hose connectors from vacuum control motor. Remove 2 retaining screws, rotate motor until shaft is clear of retainer. Lift shaft off mounting pin and remove vacuum control motor. To install, reverse removal procedure.
Removal & Installation (Defrost Door)
Disconnect vacuum hose connectors from vacuum control motor. Remove push-pin from end of shaft. Remove 2 mounting screws, and remove vacuum control motor. To install, reverse removal procedure.
Removal & Installation (Fresh/Recirculated Air Door)
Disconnect vacuum hose. Remove 2 screws retaining vacuum control motor. Rotate vacuum control motor until shaft is clear of retaining clip. Lift shaft off mounting pin, and remove vacuum control motor. To install, reverse removal procedure.