Re: Recirculation door thwack sound
Mine would also turn a full circle in each direction when I simply plugged the actuator motor in without it fully connected. Once I installed the assembly back together it would only turn a quarter circle and stop when the flap closed and turn the opposite direction a quarter circle to open the flap. The motor must sense the tension on the gear once the flap is fully open/closed and stop the rotation of the motor.
If yours is turning a full circle after you've reinstalled everything then you must not have the gears lined up or in the proper position to actuate the door properly. There is a flat part on the mating gear that needs to line up with the groove on the gear. I had to press the Recirculation button a couple of quick times to line the gears up properly.
2006 Jeep Grand Cherokee Overland 5.7L, BT Catch Can, SRT Eibach Pro Kit, 20" SRT Factory Repros, SRT Front and Rear Bumper and Side Skirts, LED interior lighting, SRT aluminum interior trim, SRT steering wheel, Shorty Billet Antenna, SRT intake, SRT exhaust with 4" double wall tips.