Re: Clicking sound from AC fan relay?
This sounds very much like the issue I just recently dealt with. When the actuator gear breaks, it allows the actuator motor to travel beyond it's normal travel limit. Since the PCM controls and adjusts the HVAC system, the computer reads this extra travel as a fault, and signals the vehicle operator of the problem by switching the blower motor on for approximately 1 minute, and off for approximately 25 seconds. (This is the probably the clicking sound you're hearing, as the motor just keeps traveling in one direction 360 degrees, and gets caught by the actuator gear stop post.)
Did you find any small bits of black plastic in the passenger foot well? That's how I found out that mine were broken.The motors usually don't go bad, but the gears break constantly. I would recommend ordering several just to have on hand until needed, since they're only about $3/ea.
Once you replace the gear and secure the actuator motor, the PCM will begin to cycle the actuator motor to align the blend doors properly. This process could take anywhere from 30 seconds to 5 minutes. If everything is lined up properly, and the PCM detects proper gear/blend door travel, the blower motor should begin to function properly again.
Oh, and I would recommend disconnecting the negative battery cable before repairing the gear problem, as the space is tight, and the air bag actuators are located just above the glovebox door. One good knock might trigger it. Better safe than sorry, right?
Hope this helps!