When the recirculation door opens and reaches the top it starts to click. I looked on both sides and doesn't look like anything is broken. Actually the clicking is worse now that I replaced the actuator.
The clicking is probably the plastic gear of the blend door and linkage jumping teeth. My guess is that the door movement is restricted for some reason. The good news is that the clicking will go away on its own. The bad news is that as the clicking dissipates the door will eventually stop moving all together (ok, really no good news here!).
Here is a couple of shots of my damaged blend door from our 2011 Liberty:
As you can see the plastic gear teeth are damaged. It clicked for awhile until it completely failed in the open position during the middle of winter.
The door its self is not replaceable. You have to buy and replace the entire air distribution housing which cost $200+ and it's a pretty big job as you need to pull the console, dash and heater core:
The dealership quoted around $1,200 parts and labor. It ended up costing me about $300, but it took a solid 15 hours or so to complete.