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On my 90 with C68, whenever you change the AC controller from off to any position, there is a small delay and then you hear a clunk. Like the vent is being held in position and then frees up suddenly. Same happens if you have it in any position (other than off) and startup the car.
Almost acts like something dropped down the vent.
I have no desire to trear down the dash to figure this one out. Any tricks out there to figure out what is causing it to stick?
There is a motor driven mix door that is sticking, or moving slowly.
I do not think my problem is the mix door. I think it is the vent door that decides on which vents to send the air to (defrost, verses heat, verse dash vents). Maybe I am wrong. Maybe the computer excersises this door when the car starts?
I was thinking that it was vacuum operated and that when the car sits the system looses vacuum. Does not occur once the car is operating and I change it off/on or to different settings. And it also happens even if the engine is off for only a little while.
Was thinking about putting in some kind of one way vacuum valve so that it would maintain the vacuum in the system when the engine shuts off. But that would probably not really help as it would be too easy.
Could be any of the doors - most of my GM cars have made a clunk when the outside air door closes for recirculation. Electronic Air does cycle the Temp Door under certain conditions. It's calculating, electronically the position of the door and it does this by opening and closing it. There will be brief delay while this process takes place. Unless you have a real big "thunk", I wouldn't worry about the noise. Toyota and the Asian manufacturers probably do a better job keeping things quiet and the noise your hearing may just be typical of Ford, GM, etc.
Your advice is probably best - I sure don't want to tear the dash down for a clunk. But this clunk is new and was never present during the car's first 14 years or so.
But the old saying, if it still functional, don't fix it seems to apply I guess.