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I'd have to check actuator movement for defrost. The actuator is electric according to my database. The actuator should be under dash at end of hvac housing.
check the actuator motor on the heater sounds like the motor is not directing the air as it should. The motor is in the center of the truck inside attached to the heater and has arms on it to move the heater and ac doors.
Mode Door 1. a.This door regulates air flow to either the dash vents or defrost/floor. If you have air flowing only through the vents with no defrost or floor, this door is failing. From our experience, this door is usually the first domino to fail. Not sure why, just is.
<!--[if !supportLists]-->4.Mode Door 2. a.When mode door 1 is set to divert air away from the vents and into the second stage of the system, door #2 chooses whether air goes to the defrost vents to the windshield or out through the floor vents in the passenger and driver's side footwells. Failure is indicated by an inability to choose between defrost and floor. b.This door turns out to be the most difficult to replace. In order to replace the door, the dash panel has to be removed. It's still better than the dealer fix because you don't have to evacuate the AC system, drain the radiator, and remove the plenum box. But it is more work than the other fixes. When this door breaks, it falls in the down position, blocking the floor vents and diverting all air through the defrost vents. From a safety standpoint, this is good since you'd most likely rather have a clear windshield than warm feet. We suspect that a large percentage of customers will just leave this door unrepaired. You will have heat through the dash vents and to the windshield, just nothing to the floor. It's inconvenient, but you'll have to make the determination if warm feet are worth the extra work to fix the door. An extra pair of socks is easier.
Possibly a bad heater blend door actuator. You get to it by removing the radio. Part is about $35 from auto parts store. Another issue due to plastic gears....... Warning -- don't drop anything back there -- use a cheap flashlight - you may never see it again.
The "blender" would refer to the blend actuators that change the flow of air from floor to vent to defrost or combinations. Properly working blend doors will allow you to direct air to the dash vents, the floor, the defroster, the floor and defroster or the floor and dash vents. If it is not working the heater will still work but you will hae no control oer where the air flows.
Hope you have the same set up, sure you do. You may have either crossed your vaccum lines or when you were putting your heater/ac box back together or you may of pinched the vents somewhat closed. Cycle through the different zones to ensure the vents are moving as your are selecting (defrost, floor, ect...) If you think the vaccum lines are correct then you may have a reassembly issue with the Heater/ac box. I had the same problem with my 2000 Dodge Ram 4x4. Use the KISS rule "keep it simple stupid" start with the vaccum lines and all your wiring to the motors, make sure everything is plugged in. Hopefully you'll find it there before going back into the box again.
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