I have a 2003 with 215K miles on it. Had it since 90K, great truck!
Part I: 3-4 years ago the (what I call) air flow control boxes (one under each side driver/pass, control which vents the air flows out of) started making noise. They still worked, but would pretty much make time almost all the time the car was running. Just a clunking, chirping, clicking every few seconds, somewhat rhythmic. Again, everything worked, just made noise. Since I am the only driver, and am alone 95% of the time in the truck, and play the radio ;), I never worried about it, just called them “my pet squirrels”. I spoke to my “non-dealer-lexus-only” mechanic that I’ve been taking it to since I got it and said the dash would have to come off to fix it, and it was a big price tag so I have lived with it.
Part II: Then 18-ish months ago I got the recall notice about the cracked dash and went in to get on “the list” at the dealership (Dec 2015). The cracked dash did bother me much, but I though, great, when they take the dash off for the repair, I’ll pay the dealer whatever their fee is to change the air flow control boxes that that time. What a great and fortunate plan!
Part III: I am still waiting to get “my turn” to get the dash fixed, but about a month ago, the air flow control boxes stopped making noise, but now I think they are stuck in one position. Here is the condition that they are now it. I get A/C out the vents on the passenger side, but on the driver’s side, it blows HEAT. I close the vents, but I some still comes through, and I some is coming through the floor vent. After another 85+ degree day in Atlanta, I am motivated to find a solution.
QUESTIONS: has anyone ever seen this issue? Is there any way to manually operate these “air flow control boxes” so I can put it in the “A/C flow mode” for the summer?? Any other ideas to keep me a bit cooler?