2006 Sienna - how to repair or replace a clicking temperature mode door actuator

This is a 2006 Toyota Sienna that is experiencing a malfunction temperature mode door actuator. The actuator is making a series of clicking noises when the temperature dial is set at 75 degrees or below. It doesn't matter whether the blower fan is running or not, the clicking noises keeps going continuously.  At 76 degrees or higher, the clicking noise stops.

First, you remove the glove compartment and locate the clicking by hearing and feeling around with your fingers. Once you located the area where the vibrations are coming from the clicking. In my case, the actuator was behind an air duct that route the air to warm the passenger's feet. Fortunately, the air duct was removable with small effort. There was ample room to remove the actuator with a short screw driver and both hands to loosen the mounting screws.

Disassemble the actuator and see if cleaning can restore it to working condition. If the teeth are broken off from the plastic gears inside the actuator, then a new replacement is probably the best way to go.

This video shows the malfunction temperature mode door actuator on the passenger side. It shows the mechanism of how hot air is passed through the door when you change the temperature dial which causes the actuator to open or close the vent door to allow hot air to pass through.

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