I just replaced my passenger and driver's side blend door motors without taking the dash out - put it back together and it all works. It used to click for a few seconds on start and I just remote started it and never heard it. We were stuck in peak hour last night and it clicked for 10 minutes straight so was time to get it done.
Before you take anything apart, make sure your climate control is off first before you disconnect everything...
The clicking noise seemed to be coming from the passenger side so I replaced that. When I put everything back together, the clicking was still there... lucky I purchased two.
I realize now that what you should do first is access your passenger side blend motor, a 10 minute job and disconnect the cable and then turn the key back on. If the clicking is gone, it was the passenger side, if the clicking is still there, it is the driver's side. Buy two and replace the passenger side regardless.
The 8mm front bolt on the passenger side motor is easy to get to. Go through the glove box to get to the back screw and if you remotely have man hands, get your wife to do it and it is out in 20 seconds.
The driver's side means undoing lots of bolts and screws. I used makuluco's video and it was pretty straightforward to get everything apart up to actually taking out the motor. I took the seats out. Carpet back, brackets off, underfloor ducts out, 3 duct screws on the driver side, 1 duct screw on the passenger side.
You get to the blend motor from the passenger side and it will have you scratching your head. I used a pry bar from the passenger side and made some room to get the motor. The front bolt came off ok. I then got a screw driver and pried down and broke the rear bolt tab off. I could then get my fingers in and pushed the red tab back and got the cable off. Getting the old motor itself out was a right front-bottom. My wife called it Daddy Birthing. There is a not a lot of room so I pretty well got a screwdriver and a pair of pliers and broke pieces off it until I was able to get it out. Probably didn't need to do that but it was going in the trash anyway. Persevere and it will happen. The main gear was missing a tooth
Getting it back in had me scratching my head until I realized why makuluco cut that part out of his video - you need to do some plastic surgery. There is a lot of unnecessary plastic in the way. I used a hammer and chisel and some pliers and removed as much as I needed. Doesn't look bad but you can see why he says not to do it on customer's vehicles. There are a bunch of fins and maybe manufacturing tabs that don't do anything and easy just to break or chisel them off. Just don't break through the ductwork and not necessary to break off the main post which a duct screw goes onto.
With those fins out off the way, the new motor goes in pretty easily if you pry down on the passenger side a bit but getting the cable back on took a little while with big hands but I got it in. The gear thing is not likely to line up at first. I just had the wife turn on the ignition and the gear arm starts moving. Use upward pressure and when it lines up, it pops in. Turn off the ignition. Replaced all the screw and bolts.
All back together and no more clicking.