'08 150 SCREW. I had the common problem where the heat was either full hot or full cold, nothing in between. Replaced the actuator and it seemed to be good. A few weeks or months later, the actuator started chattering on startup, like it was stripping its gears. Lifetime warranty, replaced it again... and the second new actuator does exactly the same thing. (I am 100% certain I did not remove and replace the same one.)

So other than a third failed actuator, what else could the problem be?

 

Did you disconnect the neg battery cable? You can ruin the actuator if it gets power before being properly installed

 

I did not, but I also did not start the truck or even put the key in the ignition until the installation was complete.

 

That may be your issue....I know every repair says to disconnect the battery, but this one really means it. If I remember correctly the actuator centers itself and if it's not properly installed before getting power, it will burn itself out

 

Well, back to AutoZone I go, and I'll disconnect this time. Thank you.

 

Good luck

 

Replaced again, with the battery disconnected this time, and so far so good. We'll see what happens. Thanks!

 

I spoke too soon! After four or five starts where it worked perfectly, the new actuator started making the "stripping gears" noise again. Crap!!

 

Here is a good video about replacing the actuator. Now sure exactly what years this applies to, but this guy says you need to remove the HVAC fuse, the fuse number is in the description of the video.

 

Thanks. Pulling the fuse would be a good idea, as it would save the radio presets, engine computer settings, etc, but I disconnected the battery, rendering the fuse irrelevant.

Both replacement actuators were made by Dorman; their website lists two different actuators for this vehicle. Dorman tech support says they have different actuators with the same body and connector, but different range of motion, and having the wrong one installed can cause this clicking noise as the motor tries to move the door beyond its physical limits.

I'll work with Dorman to figure out which actuator is actually correct - I'll bet a nickel it isn't the one I have installed - and we'll go from there. Stay tuned!

 

And for what it's worth, my clicking is very different from the one heard in the video. Where the video clicks are heavy and one at a time, "CLICK. CLICK. CLICK.", my individual clicks are lighter and much faster,
"clickclickclickclickclick".

 

Was there a part number on the original part , to match up ?

 

Dorman says the two actuators listed are for the temperature blend door and the mode door (console vs floor etc), and I have the correct part for the temperature. Suggested pulling that fuse (or disconnect battery again) for a few minutes to make it re-calibrate itself. Here's hoping.

 

The blend door itself could be binding.

 

That's a good possibility. Is there anyway to move it manually ?