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Hey all,

A while back I had a loud knocking in the passenger side dash of my 2012 Chrysler 300, which after looking into it, it seemed like it was the Dorman Air Door Actuator (604-024). I went ahead and replaced it, which fixed the problem (sort of). There was still a small whirring sound occasionally, but no where near as bad as it was. This morning all of a sudden the loud clicking is back, but much louder and faster. I assume it's the same part, but can't figure out why it didn't fix the problem the first time around. It starts first thing in the AM when I start my car and goes on and off periodically. It even does it when the car is off. I'm thinking about just removing it all together and dealing with one of the actuators just not being there, but wanted to see if anyone else had this problem.

Probably unrelated, but my humidity sensor at the base of the rear view mirror stopped working a while ago, which I replaced, but went out again.

Thanks again.
 

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hummm, could be the fan, if it became unbalance or damage. When it turn at different speed it will vibrate differently and could touch something. Or the fan bearing are worn out.
 

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It is more than likely the AC blender door actuator which sits on the passenger side just below the glove box. I have the same car and had the same exact sound/issue. Lucky for you it is easily replaced if you are somewhat handy and have the right tools. I can change mine out in less than 30 minutes (probably even faster). I have had to change mine out 5 times now and I think the last time was the final time because it hasn't made any clicking sounds since and I've used OEM parts every time except for the first time.
 
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