Very annoying and also worring problem; Clicking sound coming behind steering wheel/under dash. Cannot determine if it is one of the relays in fuse box under dash or something else (is there relays inside dash?). Happens only when engine is running. Can be regular or not. If relay clicks rapidly (more than one time in a row) it also affects rpm of the engine (voltage drops?).

Does anyone have any suggestions what might cause the problem?

Thanks in advance.

Mika, 93/94' T.Spark

This sounds like the dreaded stepper motor dying. Have you checked that? In case you don't know, it's part of the climate control system and there are two steppers in the car. It's a small electric motor with a series of plastic gears that open and close various vents and such in the car. The plastic gears are garbage and in pretty much every case, will strip and start making that clicking noise (and probably the climate control will not switch between floor vent, defroster, face vent, etc.)

You can buy a set of replacement gears for it, either buy the cheap replacement ones from Alfa and it will die on you again before much longer, or spend $130 US for a set of metal replacements from this place in Australia:

www.alfapro.com/html/steppers_home.html

I guess if it's not the stepers at all, then I've just bored you to death. ;)

Good luck,

Greg (USA)

Greg,

many thanks for your reply. Maybe I did not specify my problem well enough (poor language...sorry). I'm aware of stepper motors, but this problem is not caused by those little rascals. AC and ventilation works well without clicks and problem occurs only when engine is running.

I know that this is caused by electrical failure somewhere very close to fuse box - left under steering wheel. First I was thinking, that it is one of the relays (7 or 8 inside fuse box; heaters, foglights, etc), but problem is thst I cannot feel any of those "vibrating" when clicking. Of course problem can be somewhere else and it just makes relay somewhere in dash to operate(?). But are there any relays behind instrument panel cause it seems that sound is coming there(?).

-Mika-

There are some relays behind the insterment cluster if I remember correctly. Take it out and check it just for the hell of it. It is super easy. Also there is one in the area in front of the windshield under the plastic that was clicking once for me.
Hope this helps.
Jason

Hei,

From vincent's description of a similar problem it does sound like SOME kind of electrical thing, if not a relay...

I don't personally know of any relays up in there, but I'm not an expert at all. Why not try what vincent did, remove one of your fog lamp relays, and see if the clicking goes away. Then get ahold of a decent wiring diagram and just track it down.

The only other thing I can think of doing is to take the dash apart and start fishing...

Greg

MIKA,
I to have suffered from this same clicking sound coming from behind the dash???
I've ruled out the stepper gears as well since my ventalation system works perfect.I must tell you that i have not solved this problem yet because i've learned to ignore it,but one time i had removed the fog light relay to replace it and during that drive to the store and back their was no noise.Upon replacing the relay the noise was back!i doubt this will help you but just thought you might want to know your not alone when it comes to this clicking sound
good luck,
vincent

Fellows, if a relay is chattering you will be able to feel it with your fingertips. First, of course, check the easy ones there with the fuses. Turn on all the accessories you normally use so you load the circuits.
Yes, there are relays behind the instrument cluster, and it's easy to remove. Along the bottom edge of the cluster, where it fits against the vinyl pads on each side, there are two small black plastic plates. Slide a thin screwdriver under them and you'll have access to screws underneath. Remove them, and the cluster will lift up and unclip from the top edge of the dashboard. The wiring harness will still be connected, but you'll be able to check the relays back there.
I just hope all this applies to your cars, if they are RHD! Let us know.

Dave Jarman
Lexington, KY
(LHD) USA

Hey Dave,

You're spot on with your description (as usual) - glad you're staying in touch with the forum. The RHD is the same as the LHD.

Mika - sure the "clicking" isn't sparking? I can't think why a clicking relay which cause engine RPM to falter.

Richard.

Hi,

many thanks to all of you! I removed instrument panel during weekend (changing some burnt bulbs) and found four relays behind it (left corner behind voltage meter). Now I am pretty sure that clicking sound was coming from one of those. Only "problem" is that problem disappeared so I cannot feel which relay it is...

But does anyone know where these four relays are related to?

I suppose that when this problem occured it made the voltage drop and this further was causing engine rpm to drop(?).

I'll let you know when clicking comes back - cause I'm pretty sure it will (4 years of experience...).

Thanks,
Mika