"Interesting, I never heard this on my 09 GT but then again, it's still under warranty.
" - All I can say is, It WILL happen soon, Hope it happens before the warranty expires. There are already people complaining who own 2012 and 2013 cars that have the issue.
"What does Ford do to fix it?" - Ford does fix it under warranty free of charge, but if the warranty has expired, You are on your own! (S.O.L.)
"Sounds so common there should be a TSB on it?" - There is a TSB on it, but it basically says just to bring the car to your Ford Dealer for service... Go figure. The average charge is about $600.00 for the repair (On just one Actuator!) - Highway robbery if you ask me.
All of the (4) actuators are accessible underneath and behind the dashboard cluster. The only problem is that you have to be on your back and have a good flashlight to get the ones under the dash behind the glovebox. Mine of course was the one behind the dash cluster that went bad.. so I'll be dealing with that one, but checking the others as well behind the glovebox as well. There is some good news with this. One is that the actuator replacements from Rockauto.com and O"reilly Auto Parts are on about $30 for each actuator. The other good news is that when you have a bad actuator, You can tell it's bad by it's knocking sound. You Just have to feel the actuator to see which one knocks. That is the good news. The bad news is that you have to get on your back finally and do the job yourself! I'll take some back muscle pain VS. having to pay a dealer $600 bucks. That is a good trade off. If you are overweight and can't get on your back, Then perhaps paying the dealer is the only option, But the goal of this thread is to make is less painfull and easier for everyone. The previous poster is correct about GM Cars and Trucks also having the problem. Those actuators in the GM vehicle are differently design, but still have the same basic issue. The NYLON GEARS strip and go bad, but they are removable. I wouldn't be surprised if somewhere down the line if someone were to come out with a kit with the identical gears in a repair kit made of aircraft aluminum to finally solve the problem. The auto industry really CHEEZED out when it came to making these actuators. Usually, You'll get 3-4 years of use out of one before it finally goes bad. The good thing for us though is that the (4) Mustang Actuators are relatively easy to get to - to replace compared to other vehicles, with the one behind the dash cluster being the hardest, but even that one is not too bad. You really don't have to run any codes to find the BAD actuators, They will be knocking like all hell and will be easy to find. After installing the replacement actuators, You can cycle through the whole A/C system to see if the problem disappears. After a full cycle of the A/C system, If there is no more knocking heard, and everything works correctly, You are done. No codes need to be run to do this fix, although it would never hurt of course. Since owning my 2007 Mustang Convertible, This Actuator problem has been THE ONLY real problem that I have ever had with my car, other than having to re-glue the door vinyl on my door panels..but that was easy..and didn't cost a penny! The car has been diehard reliable with no ther complaints.
I'm going to order my actuators soon, and will start the project documenting everything here with pictures and most likely video as well. with my IPOD 4S Touch.