Had the same problem on my 2001 Super Duty.
Solution: leaking vaccume line to the auto locking hubs. It seems Ford saw fit to tie the two systems together. Once I fixed the lines to the hubs my vents worked properly.
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The air direction is vacum controlled. If you have 4X4 and ESOF ( switch in the cab) then you need to inspect the vacum lines that go to the hubs and possibly the hub seals. "default" position for air flow is the defrost position. If you DON'T have 4X4, and it's a diesel engine, inspect the vacum pump, If it's a gas engine then look at all the vacum lines from the intake manifold for a leak.
I had a problem with vacuum in my F250 diesel. It had a new vacuum pump but would kick out of cruise control every time the vacuum pressure dropped. It turned out to be the vacuum reserve cannister had holes in it.
Seems you reach a tipping point and then all the vacuum systems mess up. You might want to check the reserve cannister and any vacuum servo your 4x4 might have. You can check most of the vacuum stuff with the engine OFF using a vacuum pump. You could have a leaking vacuum pot operating the ductwork. Check your diesel vacuum pump for output and loose belts.
Some thing you could look at would be this. The control is usually fed by a vacuum line or small hose thats is connected to your intake manifold.
With a cold engine,look for a skinny vacuum hose that runs from the intake toward the fire wall . It should be going inside the cab and connecting to the A/C vent control.Some times the hose becomes disconnected or splits or cracks due to heat under the hood.
Thats usually the trouble.
I hope this helps you.
Check your vacuum pump located on the right side fenderwell. see if its running. Check the vacuum hose at the hubs for leaks or damage. repair if damaged. check for other vacuum leaks such as the grey hose going to the heater control valve.
check your vacuum storage unit or vaccum pump supply, remember diesel motors dont make vacuum like internal combustion gas powered engines do.. they have an auxilary vacuum motor and resovior to store vacuum to eliminate a lag time in vacuum supply...please rate my help..thanks...
You can use a little shaving cream on the inside of your windshield. It will keep your windshield of fogging up. It also works in the mirrors in your bathroom near the shower / bath tub. If you don't believe me, do a search in google for shaving cream and windshield. Pretty cool, huh?