Q: I am 91 miles from the nearest mechanic on this website.

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Hi there. From the other question and the information you have provided, it sounds like the actuator that you have replaced around 2 years ago has skipped teeth and is clicking when it maxes out on the rotational circuit. Remove the actuator from the blend door and operate the actuator. If the actuator moves all the way and then stops, then there could be a obstruction to the blend door and not allowing the actuator to move all the way causing it to jump teeth. If that is the case, then look around the blend door to see if there is any debris that could be keeping the door from opening or shutting all the way. If the actuator is clicking with it disconnected from the blend door, then I recommend replacing the actuator. If you still need further assistance with your actuator not working properly, then seek out a professional, such as one from Your Mechanic, to help you.

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