Had clicking when I bought the car at 66k km, one night the whole way home the thing clicked agressively, around 20 minutes time, and then nothing.
Since then went in under the steering wheel four times, replaced it twice with different dorman actuators (same part #) to ensure it wasn't part failure.
Part numbers are good, and I made sure that it's installed 100% the right way. Still - vents are not actuating properly. I'm tired of dealing with it, and I hope it's not a broken door and that I don't have to replace the whole assembly. I don't even want to bring it to the mechanic because they'll probably just quote me 1k+ for a dash removal.
Otherwise, seems I'll just disconnect and remove the actuator, and every season I'll just realign vents where I want them. 90% of the time it's defrost and feet anyway.
Last ditch ideas before I just don't change my vents for the next 5 months? Fuses, master reset of Sync? The other door actuator (temperatures are OK and no clicking). I'll disconnect battery this weekend to see if it resets. I have installed a new Sync module (had Sync 2) from another Fiesta, maybe that's the cause?
Should I order a HVAC control panel to see if it's that? It acts weirdly, as in won't show intensity of fan when turning on hi. I own a 2014 though, so usually not affected by the software issues that were on the 2016. Otherwise, did someone ever make a video for replacing the actual blender door? And not the actuator.