Clicking sound from front heat setting
Could be the vent door is getting hung up or the turning motor is bad.
SOURCE: 2002 Windstar Knocking or clicking sound from temp control switch
You need a blend door actuator. It's located behind the radio and a/c control head.
SOURCE: There is no heat comming out of the dash vents but
blend door problem or related component also check for low coolant stuck thermostat
SOURCE: When I set my temp
More then likely it's going to be a blend door actuator motor, being there all made out of plastic, listen to where the sound is coming from, thats the bad actuator motor
SOURCE: when the heat is on
the operating mechanism is playing up and may need changing ,it has a vacumn operated control arm and what i thnk is the problem is the diaphragm has split inside the unit so its not opening to allow the hot air to flow over the radiator inside the heater
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