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I have the clicking sound now (80k miles), talked to my service guy and he said that there are several blend doors. The one he replaced at 75k miles, was for the temperature. The one which now needs to be replaced is the upper one. It's going in this Friday for this, an oil change, and possibly U-joints.
Hey TheJoker,
I'm going to get this into the hands of your regional customer service manager, who'll facilitate discussion and repairs. Please send me a PM with your full name, phone number, VIN, and the Ford Dealer you're visiting Friday.
Thanks!
Todd
Todd, if you don't mind me asking, what are you going to facilitate?