The 2009-2014 Ford F-150 was introduced for the 2009 model year as an update of the Ford full-size truck platform.

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2011 Ford F-150 fan switch creates a knocking like noise under dash?

noise will go away after switch is turned to a higher speed and it just does it on ac

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I have this exact same problem on my 2011 f150. It only happens on AC and only at the lowest couple temperature setting notches.

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Donald, Found this info. from a Ford F150 forum, There are 4 electric actuators that control temperature (left and right), air recirculation, and mode. Try adjusting the controls one at a time to determine which actuator has failed. You may have to do a little investigative work to find which one is making the noise. Each has a small motor with a potentiometer that lets the control module determine where the particular door is positioned. When they fail, usually the module can't tell the position of the actuator and runs its motor looking for its signal. When it gets to the end of the gear it goes "pop - pop - pop".

Links below show/explain how to change actuator in your truck. Good luck.

I hope this helped you out, if so let me know by pressing the helpful button.

https://www.youtube.com/watch?v=D-M30Kyy...

https://www.youtube.com/watch?v=EbTivF3M...

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I've replaced the blend door actuator 3-times in my 2011 F150 and am headed to O'reilly's now to get another one! Good thing they have a lifetime warranty on the part!! I watched a couple of YouTube videos that show you how to do it. It's frustrating that it keeps breaking and has since about 2014....It IS a common problem on the F150 and other models that use the same part. The clicking sound is the broken plastic gear inside the blend door actuator (moving the knob changes the vent from cold to hot). Usually this will make the clicking sound around the last 2 "cold" positions on the control knob (the one with red and blue color indication lines around the knob). I need ALL of the cold available as I live in 115 degree summer weather in California. The Ford dealer told me that it will cost about $250 for them to do it; I do it in about 1/2 hour and the initial cost of the part was about $24.99.

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If you keep replacing the blend door acutatotor and it keep happening to you. Then 9 times out of 10 the blend door itself has probably broke which is allowing the allowing the actuator to over rotate an burn the gear out. Might want to replace the blend door.

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