So about a month or so ago I had the defrost actuator (the one way up high on passenger side of console) start with the clicking. I bought replacement part 604-233 by dorman and replaced it, started it up still made the sound but slightly different. So after I replaced it, it made so much noise I just unplugged it but if I needed defrost I have to plug it back in and listen to the damn noise. So this past weekend after reading up on it I found that they have to be calibrated (thanks for not putting that in the service write up Ford). So yesterday I tried to re-calibrate knowing I may have damaged the new one. Calibrated it and still the noise, calibrated again, still noise. So today I bought another actuator, installed it, re-calibrated it, tested without starting the car and there was no noise. I packed up my tools and reassembled and started the car to move it, I tested the heat/air/defrost positions again while wincing and sure enough when it got to defrost that freakin' noise clicking spatter was there againfacepalm2.gif. My calibration method was remove fuse 10 and 12 from interior junction box and turn key on for 30 seconds then off and wait a minute then put fuses back in and turn on key to test. Hopefully someone can help me some way, I am about to push this damn car off a cliff since I have had 2 codes for months I can't get rid of as well. If you have any knowledge of whats going on PLEASE HELP!