blend door in pluenum
Yes, possible blend door actuator, or in the blower motor & squirrel cage itself. If it is blowing air, then it would be under the dash for the blend door actuator.
I've been through this with my 2003 Explorer. The problem is the blend door actuator. The little motor, the size of a cigarette pack, has plastic gears with plastic cogs. When one cog breaks you get the click-click-click. When two or three break next to each other the blend door gets stuck in whatever position it is in when the motor goes out completely. On the 2003 the actuator is around your right foot near the gas pedal. The dash has to come out to properly fix. The part on the net is about 60 bucks. The dealership charges about 600 for the repair. There is a manual workaround on the net going through the glove box and manually setting to hot or cold each time the engine starts. Fortunately, where I live cold is considered anything below 50 degrees and mine is stuck on AC, which is needed about 10 months out of the year.
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