Try changing the lower temp sensor in the air duct on the drivers side. I bought one and never replaced it. before the part arrived I took the lower sensor out and taped it up and put it back under the dash... not in the air duct housing were it belongs. believe it or not it works so well I did not even see a need to change the thing.
It sounds to me that one of the cables or servos is loose or faulty causing one or more of the direction flaps to be left open or closed ,whatever the case may be ..hope this helps
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Same problem on mine I removed all servos and manualy shifted all door flaps still no change. the evaporator was changed for leak and doors seal's checked.
But there is still a 10 degrees difference in passenger & driver air vent
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