Watch the movie below.
What is that sound?

Dwaine
2011 XLT
3.7L

 

Someone farting? J/K never heard that before.

 

It is an actuator behind the dash. I have disconnected it. My air can only go through my vents, but I'm cool with that.

 

So, the one next to the pedal? Pretty easy to replace, I hear.

 

That noise comes from the mode door actuator linkages. You can apply a good coating of garage door opener lube on the linkages that will deaden that noise. Check both sides of the plenum for linkages that may be involved. Some models had the foam coming off the doors that can cause some of that noise if the foam traps between the door and the plenum. That would require replacing the upper plenum or reinstalling the foam with a good adhesive if the foam hasnt been torn up. I had good success just lubing those linkages real good. Dont use white lithium, as it will gum up the works when it hardens. 3M used to make the perfect light grease in spray form called Spray Lube 08878 but it has been discontinued from my understanding.

 

Motorcraft YH-1881

The correct part number.
Mine is clicking as well, and I ordered the wrong part.
The part number on the Service Manual and the Ford parts website doesn't seem to match up correctly. The part number given and the drawing were way off.