tromly

I have the same problem with my 2004, I will try to fix it myself

a002074t

The issue with these servos/actuators is their design. If you open one up, you will find that it contains a DC electric motor, 3 plastic gears (a worm gear on the motor + a coupe other wheels) with a variable resistor carbon pad on a circuit board mounted to the 3rd gear (the one the actual arm is attached to). See photo(s).

It appears with time the 3-pronged contact arms which ride on-top of the variable resistor wear grooves into the carbon pads to the point where they loose contact completely. Once that happens, there is not much you can do but replace the actuator. It would be nice if Denso (the manufacture of this thing) provided the carbon disk as a replacement part but so far I have not been able to find it.

Another option is for you to gently spread out the 3 contact points of each arm so they ride along a slightly different path on the carbon wheel. I did that with mine hoping to get another 10 years out of it. It's back in the car for a week now and so far, so good.

PS. Denso changed the design of this actuator in 2007 from a variable resistor to copper contact and rather than resistance, the car computer now reads pulses to determine (and set) the location of the arm. So don't go thinking a newer version of this from a junk-yard will solve your clicking problem. (see photos)

If anyone finds a way to get a replacement for this disk, let us know. I'm sure a lot of people would be interested.