I thought I would add a informational thread for this 996 problem since there does not seen to be a precise answer to the problem online. Chances are you have been searching Youtube and forums to see what the heck is going on when you press the recirc button on your 996. Well if you hear a clicking sound from the passenger footwell your in for some fun! What happened to your car is the recirc motor has failed, probably the plastic gear inside the motor case as shown in my pic. I had good luck getting a new motor from Amazon. Dont waste any time going through "hvac diagnostics" in hoping you will find an easy fix, you wont, its broke. The motor is located on the right side end of HVAC box under the dash right next to the body. You will have about 3" to work in. Do yourself a favor and just remove the passenger seat. There is one small screw holding it in, not hard to get to. Then you will pop out the single connector. It will then only be held in by 2 things, a slide out plastic shaft about 1/2" long connecting it to the inside door then another plastic arm with a pop in rotating connector. Its a pita but with a long flat head screwdriver you can pop it off. Getting it in is a matter of lining up the shaft with the door then popping the other arm on. Good luck and hopefully you have smaller sized hands and a limber back!
HVAC recirculation door, flap, motor clicking. What it is and how to fix.
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YOUR RESEARCHHVAC recirculation door, flap, motor clicking. What it is and how to fix.
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