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There are electric motors that move blend doors in your dash board. The blend doors control the heat/cool ratios as well as the location the air will blow from. It's very common for the doors to break or the motor to fail and require replacement which can be costly.
that noise you are hearing is the blend door motor. A blend door motor switches from heat to a/c and what vent to blow it out of. it is located on the heater box under the dash
i just worked on a 2004 explorer. it had no heat and the ticking sound of the blend door motor. replaced motor. took care of the clicking sound. but still no heat. tinkering around for a few hours reading forums and doing some test. i never gave it the thought to KEEP IT SIMPLE STUPID! it was low on antifreeze. i added some earlier but after running it and bleeding the lines and topping off the water it blows hot again.
it is called a blend door acuator problem. it is what moves the door from hot to cold or vice versa. it is usually way up under the dash and is very hard to get to.usually requires dash disassemly. do yourself a favor and take it to a mechanic. it will save you $$$ in the long run.
The clicking is the air temperature blend door motor, most likely the motor will have to be replaced the blend door checked to make sure it moves freely, this repair requires the removal of the dash assembly.
The blend door (mode door ) is a very common issue there is even an associated TSB t(technical service bulletin) it has to do with the blend door becoming warped and binding the accuator. In an opened or semi-closed position
The concern lies in the temperature blend door. Most likely if it is clicking the door is broken where the motor shaft (the motor that actuates the door) goes into the door. Replace both the door and motor ( unfortunately from Ford the whole heater box needs to be replaced) or an aftermarket such as Dorman may have the door separate. The entire dash needs to be removed for the repair so it is quite costly.
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