Anyone else have this annoying problem? Usually when truck has been sitting all day, i go to start it and there's a very loud and slow clunk...clunk...clunk noise coming from the dash. I know it's related to the ac/heater fan, since it ceases when i turn it off. It sometimes goes away after 10 minutes or so. Is there a baffle in there somewhere that may be flapping open/closed? I didn't think it was the fan because it's not a fast klunking sound, it does speed up slightly if i turn the fan up. just annoying more than anything. Thanks

 

your recirc door is closest to your blower motor and could be weak causing it to flap.
try changing from recirc to non-recirc and see if the noise changes

 

Pull the blower. It should be held in with 3 or 4 screws under the passengers side of the dash. Takes less than 5 minutes. You can feel around in there to see what it could be. Also, you may be suprised what you find- bugs, leaves- stuff like that.

I replaced mine in my 2001 because it was squeeling like mad.

 

Similar thing happened to me. It sounded like a fan belt had broken loose clunking around. The stealership had to pull the dash and fix a broken recirc. door that came off.

 

Mine, when I start the engine, I hear a loud bang under dash. Dealer said the blower door is broken and I need to come up with 6-700 to fix it. I never did. 2 years later, everything still works fine.