IS THERE ANY PROBLEM WITH YOUR A/C CONTROLS? -DOES AIR BLOW OUT WHERE ITS SUPPOSED TO AND DOES TEMP CONTROL WORK? - IF A DOOR IS STUCK OR MOTOR COUPLING FOR DOOR IS BAD IT WILL TICK OR POP TRYING TO MOVE
The motor that opens and closes that door has a two wire connection and presumably the only way the computer knows when the valve is open or closed is to sense high (stall) current in the servo motor. This is a poor design because it stresses a plastic secondary gear in the servo and can cause a couple teeth to break off. Now the gears skip (making the clicking sound) and the motor never stalls so computer never shuts it off and the clicking continues. It's an expensive part (of course) but I fixed mine by opening it up and reversing the secondary gear so that the bad section is never encountered in the 180 degree travel. To find it, take off the glove box and it'll be on the left side under there.
Turn the circulate button off! The clicking is the baffle door trying to shut when you circulate the air instead of using fresh air. It closes all the way and then for some reason the gear keeps turning and makes a clicking sound. We just never use the circulate feature and never hear the clicking!!
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