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I have what is best described as a rattling noise inside our 2006 EXL from the HVAC behind the dash. When the temperature controller is set to full hot or full cold there is no noise, when anywhere in between i hear the noise. Anyone else ever encounter this? Blend door?
 

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2004 Pilot EX-L
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Blend door actuator. It makes a gurgling or grinding noise. Caused by worn out or fouled contacts inside the motor mechanism. You can take it apart and try to clean it, but mine was beyond repair, so I bought one on Amazon for around $25 and replaced it. There are lots of helpful youtube videos about it.
 
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