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What could a loud clicking noise in the side panel of 3rd row seat 2004 Ford Expedition be when rear air is turned on?

A loud clicking noise in the side panel of a 3rd-row seat in a 2004 Ford Expedition, specifically when the rear air conditioning is turned on, strongly suggests a problem with the rear air conditioning system's actuators or related components.

Here's a breakdown of the likely culprits:

* Blend Door Actuator: This small motor controls the direction of air flow (face vents, floor vents, etc.). If it's malfunctioning, it might be clicking repeatedly as it struggles to move the blend door. This is a common failure point in many vehicles.

* Mode Door Actuator: Similar to the blend door actuator, but this controls the *mode* of airflow (defrost, vents, floor). A faulty mode door actuator can also produce clicking sounds.

* Airflow Control Actuator (if applicable): Some systems have an additional actuator to control overall airflow volume.

* Wiring Harness: A damaged or loose wire in the harness supplying power to the actuators could be causing intermittent contact, leading to clicking.

* Actuator Linkage: The actuator itself might be fine, but the linkage connecting it to the blend or mode door could be broken, binding, or loose, causing the clicking sound as the actuator fights against this resistance.

Troubleshooting Steps:

1. Listen Carefully: Try to pinpoint the exact location of the clicking. Is it coming directly from the actuator itself (usually a small box attached to the ductwork), or from somewhere else within the panel?

2. Access the Panel: Carefully remove the side panel of the 3rd-row seat to visually inspect the actuators and wiring. Look for anything obviously broken, loose, or out of place.

3. Check for Obstructions: Make sure nothing is obstructing the movement of the blend or mode doors.

4. Test the Actuators (Advanced): If you're comfortable with automotive repair, you can try testing the actuators directly with a multimeter to see if they're receiving power and functioning correctly. This requires some electrical knowledge and safety precautions.

5. Professional Diagnosis: If you're not comfortable with DIY repairs, it's best to take the vehicle to a qualified mechanic or HVAC specialist for diagnosis and repair. They have the tools and expertise to properly diagnose and fix the problem.

Ignoring the problem could lead to further damage or complete failure of the rear air conditioning system. Addressing it sooner rather than later is recommended.