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CHECK WHETHER YOU LEFT SOMETHING LOOSE IN THE GLOVE BOX,BEHIND GLOVE BOX IS THE HEATER MOTOR,CHECK IF ANYTHING IS LOOSE,BROKEN. ALSO THERE SHOULD BE THE PASSENGERS AIRBAG UNIT,SEE IF IS NOT THAT,WITHOUT TOUCHING IT,AND THE IGNITION OFF POSITION.
possibly a screw was dropped, try removing the glove box and take alook. tap around the area gently with your fist and see if you can create the rattle, this will give you the area to look for.
You have a stripped gear on the stepper motor. This motor opens and closes the fresh air intake. I replaced this part over the weekend. Part was @ $160.00. You have to remove the glove box and disassemble the blower motor to get to the part. It was a little tricky and if I had to do over again, I may have paid for the labor or would have lived with the problem.
It could be just a bracket...when metal heats up it expands..you could have just a simple loose piece of bracket...remember..if it ain't broke don't fix it....I had a pickup that did the same thing too me..drove me nuts..I found a couple pennies in the glove box that were making the noise..always check the simple things first
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