Hi all in Ford-Land, 2005 Explorer V8 Limited, electrical issue, Regular (about 1/sec) "flapping" noise

[JdL56]

Hi guys, my Explorer V8 Ltd is a favourite! nearly 400,000 kms travelled! No major issues!
Now has an electrical "Flapping noise" about 1 per second whilst driving. Noise seems to come from under middle of dashboard.
I recently discovered that this noise can be "created" by simply turning on the headlights with nothing running and no key in the ignition!
What is it? how to fix it?
Will attach (if possible) a short video/sound grab.
thanks and cheers,
John

 

[mountaineer2004]

Hello down under! Unfortunately, I don't have the answer to your problem.
I'm sure others will chime in. That sound video would help.

 

[J_C]

I'd guess it's your blend door/actuator making the noise, but not sure what is causing it to activate like that if not the actuator itself. Does it still do this if you set the climate controls to opposite ends of the temperature extremes?

Do you have manual or auto/EATC climate control? I'd guess the latter being an Ltd. Someone with a workshop manual for your 3rd gen Explorer might be the best help but I only have this for a 2nd gen, which "might" be similar enough (might even be the same but IDK) to track this down, attached:

 

[traveler]

That definitely sounds like a Blend Door. My Explorer did it (Had it repaired), my Expedition does it, and my wifes Fiesta does it. Needless to say, its a common problem with Ford Products.