AF Actuator??

[asphaltman]

Here is my story.....This last summer my '08 had a popping noise down by the passenger floor board..after reading on this site, I was sure it was the TSB for the heater core issue...well turns out the dealer diagnosed it as the AF actautor box and R&R the unit......it fixed the issue. A month or so later I started hearing a noise similar to a CD player moving tracks...upon listening closer I found it sounded like the motor adjusting the actuator box when the AC system was in auto mode....the dealer agreed and R&R the box again ( this is a bigger job as it requires a dash pull ) anyways a few more months have been buy now I started to hear what I thought was an air door closing...its a pop like noise...I am used to hearing this same noise when you first start a truck and the AC system turns on, or when you switch from DEFROST to VENT etc.....sounded like the air door....anyways it was making this noise every 30 sec on the dot....I was now over 36k but they said if it was related to the previous issue they might be able to warranty it...took it back in and they pulled the dash, but instead of replacing the AF actuator box they now claimed this new sound is not an air door closing or box but rather a noise from a surge in the line when the AC compressor kicks on.....so they just dammpened the area with rubber so it reduced the sound of the noise, but its still there...well here is my issue...coud this be because the dealer does not want to fight with Ford for a warranty fix since I was over the 36, and its the dealers way of getting me out of there....or could this be a real problem.....I just cant believe if it is indeed the AC compressor surge, why I never heard that air door type noise before....I also pointed out that it did it when the AC was off...but they said regardless if the system says "AC" or not, when its in auto the AC compresor could be on at anytime...I just dont believe this.....

What do you guys think? HAs anyone experienced this??