by mark » Tue Apr 15, 2008 12:47 pm
WOW, this is what it is for sure. I had the same problem the day after I bought my car!
Basically, a 'tooth' has broken off a cog in a little black box behind the glove box, (top left) that operates the the aircon, 'air in' lever from outside.
Every time the ignition goes on all these little cogs spin down inside the box to their first setting or something like that and when a tooth breaks off a cog it spins down too far and that's the clicking noise that you hear. It's realy annoying!
So take down the glove box by pushing the two side panels in slightly and releasing- yes empty contents of glove box before this!
Then lying on your back with a short philips screw driver unscrew the little black box (its the one with the brass lever going into it), its feckin awkward to get at but comes out easily enough.
Remove box and open carefully, it's semi sealed and one or more tabs make break off when you have opened it so be careful.
You'll see a load of cog wheels and either one is broken totally or one tooth has broken off and is in the box somewhere. It's tiny so a tweezers and super glue are a must. Carefully glue this back on and replace all back together.
First time I did this, it lasted a week and then started again. Removed box again, re glued cog and it's perfect!
Hope that's of help, if you have trouble sorting it give me a shout and i'll give you a dig out.