HVAC Clicking in Dashboard AFTER Getting Both Blend Door Actuators Replaced

[DangerRanger95]

Hi All,

I'm stuck on this one and hoping someone might have some insight.

I have a 2021 Ford Ranger Lariat with about 37,000 miles on it. I bought it used in December 2024 with around 27,000 miles. It was in great shape—just off a 3-year lease and looked like it had been garage-kept.

A few months ago, I started noticing a "clicking" sound coming from the dashboard. It gradually got worse, and I also felt like the A/C wasn’t blowing as strongly. I took it to the mechanic who diagnosed the issue as faulty blend door actuator motors. Since they had to remove the dashboard anyway, I agreed to have both actuators for the dual-zone climate control replaced.

Fast forward a few days after the repair, and the clicking came back. It's now been about two weeks, and the issue has gotten worse. The clicking happens when I adjust the temperature on either the driver or passenger side, and sometimes it just starts clicking randomly with no clear trigger. The only consistent thing is the inconsistency—sometimes it's quiet, other times it's nonstop. And sometimes it'll even have a regular clicking cadence of 1 click every 5 or so seconds. I will say, though, mornings seem to be the worst time for it.

Any ideas? Replacing both actuators and still having the same issue makes me wonder if something else is going on.

Thanks in advance!

Sponsored

 

[Dr. Zaius]

There is a TSB for this issue, but unfortunately you are likely out of warranty so it would be an expensive fix.

The entire heater box has to be replaced, not just the blend doors.

The box warps and binds the doors.

HERE is a thread detailing it.

Long read.

 

[Techcargt]

Sometimes just replacing the actuators will work,but if this happens under warranty Ford requires that the entire HAVC unit be replace as the plastic parts warp and the doors begin to drag which causes the little plastic gears to wear out or break .

 

[DangerRanger95]

Thanks guys, I'll have to dig into this with the heater box. I've read that replacing that unit is very labor intensive and expensive...

 

[airline tech]

I was in the middle of linking threads, but just in case the above posts did not get these.
This is a known issue but normally only up to 2020.

So this is most likely going to be bad news and the Heater Box itself is the issue (binding internally) this binding causes the actuator drive levers to bend / flex and then the guide pins drop out of place (This is the clicking / snapping) sound.
Older systems this would be the actuators but with the Ranger, it goes deeper than the actuators and its what the actuators are driving has proven to be the issue.

Now: It may be a simple (Recalibration) of the actuators is all that is needed, doubtful but possible.
Pull Fuse #12 in the BCM Fuse Box (Cabin) for 5-Minutes and then reinstall, this forces the actuators to cycle full travel and find its end of travel points.
another
Perform a FCIM (Self-Test) Reset - this also forces actuator cycle.
If this works its good news, if not read the threads below for very detailed information about this issue.
These include (working) band-aid fixes that partially fix the issue to at least get it back to operation, but the only real fix is to pull the dash and replace the (Heater Box) section of the complete assembly.


HVAC / Climate Control- Issues - Operation - T-Shoot and Breakdown | 2019+ Ford Ranger and Raptor Forum (5th Generation) - Ranger5G.com

SSM 49264 - Climate Control Temperature Will Not Adjust With Clicking/Snapping Noise From The Dash | 2019+ Ford Ranger and Raptor Forum (5th Generation) - Ranger5G.com

 

[Tom_C]

I have an Oct build 2020, purchased new in spring 2021. I started getting the clicking in early 2024 and took it in to check the actuators. They said it was the heater box and it was replaced with about a month left on the 3yr warranty.

 

[DangerRanger95]

I was in the middle of linking threads, but just in case the above posts did not get these.
This is a known issue but normally only up to 2020.

So this is most likely going to be bad news and the Heater Box itself is the issue (binding internally) this binding causes the actuator drive levers to bend / flex and then the guide pins drop out of place (This is the clicking / snapping) sound.
Older systems this would be the actuators but with the Ranger, it goes deeper than the actuators and its what the actuators are driving has proven to be the issue.

Now: It may be a simple (Recalibration) of the actuators is all that is needed, doubtful but possible.
Pull Fuse #12 in the BCM Fuse Box (Cabin) for 5-Minutes and then reinstall, this forces the actuators to cycle full travel and find its end of travel points.
another
Perform a FCIM (Self-Test) Reset - this also forces actuator cycle.
If this works its good news, if not read the threads below for very detailed information about this issue.
These include (working) band-aid fixes that partially fix the issue to at least get it back to operation, but the only real fix is to pull the dash and replace the (Heater Box) section of the complete assembly.


HVAC / Climate Control- Issues - Operation - T-Shoot and Breakdown | 2019+ Ford Ranger and Raptor Forum (5th Generation) - Ranger5G.com

SSM 49264 - Climate Control Temperature Will Not Adjust With Clicking/Snapping Noise From The Dash | 2019+ Ford Ranger and Raptor Forum (5th Generation) - Ranger5G.com

Thank you for the detailed response. Unfortunately, we have already reset / recalibrated the actuators which did not fix the issue. Based on what I've been hearing back from this group, I think you're right, it's unfortunately the heater box.

 

[Dereku]

Mine clicks too. I just ignore it with the radio. Until I lose the ability to control the temp, I am not ripping my dash apart. And I am now my own warranty….

Sponsored