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I have the same problem in an 03 Eddie Bauer Expedition. I still haven't pulled the full rear panel off but by removing the cup holder and the top panel (both just popped off using a flat-head screwdriver) you can access the rear compartment. Because the clicking was our main issue I unplugged both of the white boxes and the clicking stopped while still blowing cold air. Obviously this is just a band-aid because you can't adjust the temperature any warmer because my blend door is stuck in the cold position so it is all cold all the time. So I will still have to remove the full rear panel to get at the screws to replace the blend door and actuator, but in looking around inside I didn't see any screws holding the rear panel in place it looks like it just has pop fasteners holding it on. The fix appears to be nothing more than removing 4-5 screws on each of the white boxes pulling it off and placing the new one on and plugging them back in.

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15y ago

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