Having problems with your 2003 Ford Expedition ?

Have 2003 Ford Expedition 4WD. When I turn the blower fan on to speeds 2, 3, or 4, there is a terrible rattling noise. No noise on speed 1. Gets worse from 2 to 3 and from 3 to 4. Is there something loose or is the blower motor shot? How do I get to the blower motor to see if something is loose. Thanks, Ken

Posted / edited by AnonymousUser on : 22-01-2018

Answers :

The blower motor is located under the right side of the dash. It is only held in by a few screws and an electrical connector. (Sounds REAL EASY Huh?) However, on your vehicle, you will have to remove the door scuff plate and the right kick panel trim (They are only held on with clips and simply pull off) so you can pull the carpet and padding back so you can get enough clearance for the motor assembly to come out. This is the hardest part...the carpet and padding does not move very easily. I have personally found it helpful to pull the carpet back and take a razor blade and "****" the padding along the transmission tunnel so it will pull back easier. (It won;t show after you put it back in place and roll the carpet back over it.) The padding is about an inch thick and the rubber-like outer surface is really tough, so make sure you have a couple of very sharp razor blades on hand.
IF you look under the dash where the noise is, you will see the bottom of the fan motor. There are three screws that hold it onto the plenum. Take those screws out and the whole thing comes out in your hand. You either have something that has fallen into the defrost vents and landed in the fan or the fan is loose from the shaft. If you cannot find anything wrong with the unit that comes out. Look into the hole that it goes in and see if there is something foreign in there.
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