2006 Sienna - how to repair or replace a clicking temperature mode door actuator

This is a 2006 Toyota Sienna that is experiencing a malfunction temperature mode door actuator. The actuator is making a series of clicking noises when the temperature dial is set at 75 degrees or below. It doesn't matter whether the blower fan is running or not, the clicking noises keeps going continuously. At 76 degrees or higher, the clicking noise stops.
First, you remove the glove compartment and locate the clicking by hearing and feeling around with your fingers. Once you located the area where the vibrations are coming from the clicking. In my case, the actuator was behind an air duct that route the air to warm the passenger's feet. Fortunately, the air duct was removable with small effort. There was ample room to remove the actuator with a short screw driver and both hands to loosen the mounting screws.
Disassemble the actuator and see if cleaning can restore it to working condition. If the teeth are broken off from the plastic gears inside the actuator, then a new replacement is probably the best way to go.
This video shows the malfunction temperature mode door actuator on the passenger side. It shows the mechanism of how hot air is passed through the door when you change the temperature dial which causes the actuator to open or close the vent door to allow hot air to pass through.

[@eduardodiaz1102]

I have the same problem 2 mechanics gave a quote about $300- $400 to fix this problem thanks to your video I going to try to fix my self this weekend i will let you know if I fixed it thanks

[@bmobmo4963]

Great video, helped me lots. Had the same problem 😊😊

[@torstenkonnopasch7343]

I had the same noise for almost a year now. The mechanic warned me that the search for the defect would cost a lot. That's why I never had the confidence to search for the defect on my own, but your video motivated me and it was very successful. The grease on the graphite tracks seems to get pushed aside after how many years and the resulting fricition produces graphite dust mixing with the grease, making it electrically conductive. After removing the grease I have noticed that the tracks were already quite used up, especially in the position where the "clicking" happens, to the extend that the underlying plastic is already visible. Nonetheless I decided to give it a try. There was enough clean excess grease in the housing near the plastic gears as TommyTFC said, which I spread on the graphite tracks and also on the sprockets and bearings. After reassembling everything I connected it and everything works perfectly now. Lesson learned: The earlier it's fixed the better, because the tracks get used up even faster from the excessive movement. Kudos for the selfless service of providing this very helpful video! Thank you soo much! - Torsten from Germany, 2006 Sienna AWD Limited at 95.000 miles

[@paulino181]

Thank you for posting the video. I have a 2007 Sienna with the same problem, and I was able to fix it the same way you showed. I suspected it was the blend door actuator, but I never would have thought to open it up and repair it. I was just planning to replace it. Saved me a bunch of money.

[@towzik1]

I am having the same problem I will fix it myself THANKS FOR THE VIDEO

[@jeremyward493]

Thanks for posting this video. It help me determine where the actuator was, so I could get heat to come out the passenger side and not just the driver side in my sienna.

[@johnbanner2522]

This is an excellent video. Informative, to the point and no superfluous nonsense. Well done.

[@TallStarlite]

Thank you, I was going crazy trying to figure out where this noise is coming from and all I did was clean the contacts and re-lubed them and good as new. Your the Man!!!!!!!!!!

[@sanjaymehta5882]

Thank you for posting the video. Your video was very useful. I was not getting click. It was grinding noise. Almost Like coolant boiling in heater coil. I cleaned the disk gently with paper napkin. It as too much carbon deposit. Used rubbing alcohol to clean the three contacts. I tested before installing. All good now. No noise. Additional comments. 1) air duct removal was not obvious. There is a plastic clip below blower fan motor. Just pull it with screw driver and nose plier. 2) I broke two clips. I use cable ties to secure it. 3) put a marking before open the actuator. It will save time to put it back. Best wishes.

[@bobbyconway1965]

Thank you so much!! Luckily I was able to fix my actuator by plugging in the wire harness. But I wouldn’t have figured it out without your video. 👍🏻👍🏻

[@TommyTFC]

This is great! I've been listening to the ticking from the passenger blend door for months and the mode control actuator for years. I never knew where the actuators were or how they worked. I took them both out, cleaned and lightly sanded the three graphite tracks on the final drive gear then used extra grease inside the unit to re-coat tracks. They work perfectly. They stop where they are supposed to and don't jitter. Very happy. Many thanks!

[@terryboyd5586]

Mines on heat blow cold air out of the driver vent by the window.

[@bryanfreeman3044]

Good video. Liked your explaining everything. The temp the motor actuated depends on the outside temp and temp in the car. Mine right now is always full heat unless I turn the temp all the way down because it's below freezing outside and the van hasn't been running. Couple little things. Use dielectric grease on the electrical contacts. Over time the lithium grease will corrode the contacts and could damage the plastic gears. Dielectric grease is the same stuff you put on your spark plugs boots. Also I found it easier to get the motor apart by jamming a toothpick under each clip then prying it open. Didn't break one clip. Also should clean with electrical contact cleaner versus WD-40.

[@rayl5074]

Great video, I'm hearing those noises on the driver's side and had no clue what it was.

[@efg3657]

Best video I’ve seen on this. Thanks for explaining it well!

[@garygalletta5093]

Really a great video. Thank you! All your info helped make short work of this repair. After cleaning the gears, I noticed some the contact material was worn down to the underlying plastic by the copper contact arms. I chose to ever-so-slightly bend the copper contact arms a bit left and right and additionally spread out the tiny finger at the end of the contact arm so they would 'potentially' rub on a new path where there was remaining contact material on the gear. It seems to have worked. I did apply lithium as you did to all the gears. Thanks so much - you're a great teacher! : )

[@MoabYoda]

You sir are my hero! Thank you!!!! I had this same problem and you helped me fix it.

[@johnc.7791]

Your video was amazing because I’ve been dealing with this noise for over two years I’ve been to mechanics and everywhere else and everyone was trying to charge me an arm and a leg I did exactly what you did took it apart cleaned it and it works perfect thank you so much

[@williamblack7268]

Excellent clear video. Can repair my 2001 now with ease. Thought it was the seals on the door sticking and worn but now realize this is what it is.

[@jgr552]

Thanks man! Your video helped me out a lot.

[@loobwan3963]

Oh, I have the same issue not hot temp, thank you for sharing and posting this video, helps me, thanks

[@brucewilliams6292]

Thank you so much for taking the time to make a video. Merry Christmas.

[@runalong]

Fantastic video!! I have this problem plus another AC problem of my 2004 Sienna has a broken mode damper actuator that doesn't adjust between defrost, face, and feet for air location. Your video shows me how easy it is to get to this servo/actuator blend door part that controls the passenger side air temperature!!

[@benholdin]

Mine does the same thing..was it the passenger side or drivers side that fixed your problem…right now I’m not getting ac at all, and the heat works only from the dash, no defrost or feet…I just took apart my actuator but it looks different from this…the big gear doesn’t just pop off like that..I’m not sure how to get into without breaking it..

[@penneytaylor9285]

Thank you so much for taking the time to post this, it has really helped us!!!

[@adrianrivera6517]

Bruh you a life saver i wish i can say thank you in person

[@digitalkov]

Excellent video. Thank you.

[@as631]

Great video; thank you. Have something similar in my Toyota FJ Cruiser. Many thanks for the insight. Have something very similar in my '07 Toyota FJ Cruiser and hope I can repair and not drop >$150 for a new OEM part.

[@tacitusunum1668]

Thanks Sean! I have the same issue. Great video!

[@ronniestephens1151]

Thanks. This was exact problem!

[@sk8manofjapan]

good job for making this video. My 2006 prius has the same problem.

[@stevehill4594]

Great job on a helpful video !

[@TheShakir98]

Thanks, I don’t know why I didn’t fix this before

[@miniolito]

Thank sir, your video help me a lot.

[@AdventureWithDanan]

Thanks Sean! Very helpful video!

[@Jericho_bella]

My 2017 has this passenger issue thank you I will clean mine and hope it saves me money

[@user-pb7tf1nd5o]

Thanks for your help from Kakakhstan

[@Khmerrommantic]

great video and thank you

[@abuzaid8846]

Awesome video. Well done.

[@michaelacevedo941]

Thanks great video

[@sacariasamor4079]

Buen trabajo

[@11020tony]

Very good, thanks you.

[@dobsve]

Great! Thank you!

[@ctlaw8344]

Thank you!

[@rikitakeshita6594]

This might be a temporary fix, but the contact strip on my part (and Sean's) is worn through and the needs to be replaced. Look at the video at 4:25 as Sean is pointing to the gear with the black/gold finish. At the bottom, around 6 o'clock, you can see his is worn through also. See the gold grooves in the black traces? That's evidence the conductive strips are worn off and this repair will not last. Nice video that easily shows how to replace and possibly repair the part. Well done, it's just that I don't believe the repair will last. Think this part # is FOUR SEASONS 73211

[@PorscheSpeedster-kz6nc]

You are awesome. Save me several hundreds of dollars!!! Thank you!

[@Niftynefty]

Thank you

[@FerrisBueller-sj5sc]

TY!!!!!!!

[@patpatpat999]

$25 aftermarket part. Replace it. Can’t tell because of the grease, but it looks like the “tracks” are worn through the semi-conductive paint to the tan circuit board material. Cleaning is a temp fix, it will fail again. (Passenger side Toyota pn: PP-GF20+M20)

[@triciat8124]

Thank you for this video! Very informative. Just wondering if you have the part number

[@mihailmihaylov3631]

Great video. God bless you in the name of Jesus

[@catalinp9176]

Is important the polarity of the motor conectors?

[@elvisfrankjm1]

Hi thanks for your video I have a question for you di you know the part number by any chance?

[@florenciomendez8139]

There are so many good videos and yours is one of them.

[@mariosanchez-sj9yv]

I used a flexible wand with a Phillips tip and drill

[@collinmorris]

is this heat/cold actuator for just the passenger side? or does it work for both?

[@CuBabies]

Hi Sean, great video, I have the same problem. I am having trouble removing the heating duct, I spend over an hour trying to wiggle it out without success. Do you have any tips on removing the Toyota sienna heating duct 55823-AE010?

[@PorscheSpeedster-kz6nc]

Same here. You gotta get forceful with it.

[@rayl5074]

Great video Sean! Just wanted to know that the sound on my 2006 Sienna (like yours) it is on the driver's side. Base on what I see, does it have 2 flap motors (one for driver and one for passenger) ? Do I do the same thing but this time on the driver's side? Thanks

[@kristofererickson1779]

Yes

[@andrewsnider4098]

@rayl5074 I am just curious if you have advice on replacing the driver’s side flap motor? I see that mine is not working. There seems to be metal brackets in the way to access it. Thanks.

[@jamoe4802]

Same issue on my 07 Sienna

[@pappascw]

Does this door just adjust the heat for the passenger side? I have a clicking sound that’s sporadic but I’m not getting a good heat in either side. On passenger side tho it is colder than drivers side.

[@ogando88]

Chuck Pappas I have the same problem and also would like to know

[@pappascw]

@@ogando88 I had to replace both of mine. Look on sienna chat a guy shows how to pull the motor out of another one and put in the bad one. Saved me a crapload of money

[@runalong]

If you have a single zone (not dual zone) AC system in your Sienna this controls temperature for everything up front. Not just the passenger side. If you have the same dual zone system just like what the video showed, then yes, it is only for the passenger side. If you have a dual zone and both sides aren't working correctly, then there is a twin actuator/servo on the driver's side in a similar location. You have to remove a small panel to get at it. The blend door servo (adjust temperature) on the driver side is easy to remove. The servo that controls mode (defrost, face, floor) is on the driver's side also. It is higher up and harder to get at.

[@cedenk]

@@runalong This one is 3 zones, right? Driv/Pass/Rear ?

[@runalong]

@@cedenk true, good callout. I'd forgotten to mention that. I was only thinking of the front climates when I mentioned dual zones.

[@rocktman81]

Anybody do this on a 2008 (or maybe 2009/2010)? For the life of me, I can’t wiggle the black boot out. I’m REALLY putting a lot of pressure on it, and trying different angles, but can NOT wiggle it out. Maybe there’s an additional obstruction on the 2008 and up?!?! 😢

[@DebtFreeCars]

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[@shoukatalimaredia5420]

Hi dear they make new Toyota sienna like junk older cars and van more realizable I know work more than 35 year

[@DanRaabecoach2014]

There are three servos in this area. Do you know how to reach the other two? How did you know which servo was making the noise? [e-mail]