Heater Door Noise

Hi, I've got a 2004 Cavalier and when the heater is turned on it makes a clicking noise (sounds like someone on a snare drum playing over and over again) You can feel it if you touch the bottom of the Heater/AC module on the passenger side of the car above your feet.
It stops when you turn the heater control to the recirculation position.
My guess is it's the recirculation door actuator motor, but I can't find it through NAPA or any automotive parts online sites, does anyone know what the Chevy part number is for this, and/or a parts blowup of the HVAC module? Also, the factory service manual I've got says that the entire HVAC unit needs to be drained of 134 and removed from the vehicle to replace this actuator, does anyone know if it can be done without removing the entire unit? From the few pictures it shows of where the actuator is, that part appears to be near the top (that's why I'd like to see a parts blowup if possible).
Thanks, Pat

I am in the same boat, anyone have help, more information diagram, how to disconnect if it is in the outside air position?

I never did find any diagrams on it, but over on the passenger side near the door hinge if you reach your hand up as far as you can beside the HVAC unit you'll barely be able to feel an electrical plug (If you have big hands you might need to have someone else try it) If you carefully unplug this plug the noise stops. My Air conditioner and heater still work fine so I haven't gotten around to fixing it any further than that.
Pat

I'm so glad you followed up, I've been trying to figure this out for so long! I just went outside and unplugged what I think was the actuator based on your instructions. I hope this works!

Hi, I had the same problem in my 05 Cavalier a few months ago, I have not gotten up and repaired it yet, because i have been busy, and you can make the Clicking stop. The problem will be in your A/C Actuator, Which, if you have the A/C or Heater Blowing method on the recirculation setting, and thats the only Setting that has the Clicking, then You need to change the A/C Blend Door Actuator. It is a tricky task, the Actuator is back in the fire wall under the dash (behind glove box). easiest way to access is from bottom. The reasoning for the clicking is because the teeth on the inside of this Blend Door are worn down, and slipping, this causing the Doors to continuously open and close.

[IMG http://info.rockauto.com/getimage/getimage.php?imagekey=1989748&imageurl=http%3A%2F%2Finfo.rockauto.com%2FRB%2F604-109-007.jpg IMG] Idk if this picture will go through, but if not, a link where you can see what the actuator is is here: http://www.rockauto.com/catalog/x,carcode,1434209,parttype,10721

Good luck on the repair. It isn't anything that will destroy your car, will just get annoying. Best of luck!

I appreciate the help. I was able to unplug the actuator but reaching up behind the glove box from the passenger side feet area. It is stuck open but the clicking has stopped and I can use my defrost in the winter which is all I care about.
Thanks again!

Lol, Good job, No Problem Man!

Now the TRICKY part! REPLACING IT ! Does anyone know how to replace it??? I cant even SEE the thing to replace it! I even went to a junk yard , and took off a cav dash AND airbag and STILL couldnt get to it ! Is replacing it without being able to see the only way ? Or chop a hole in the glove box ? Kidding of course , but seriously ?? How ? http://staticaf.com/vbulletin/images/icons/icon8.gif

I've got the factory service manual and it says to pull the dash off, drain the refrigerant from the AC system then pull the AC unit out of the dash and it's on the back there somewhere (It's been 6 years since I looked at it) I've seen pictures showing it behind the glove box somewhere but if I remember right it isn't like the pictures show.
That's why I didn't bother with it anymore after I pulled the plug off; I've been driving it for 6 years like that and I can't see any difference plug on or plug off, all the heater and AC works like it's supposed to (Even Max AC)

You got it man ! I did what you said and everything works just like normal ! With no clicking ! The garage wanted $450 to replace it so... You ROCK!! 1000 Thank you's !