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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.
Locate the fuse box under the dash panel. Pull the fuses one at a time and inspect. They are very hard to judge if the fuse(s) are blown unless you pull them out to inspect.
Similar issue with my friends Dodge. Its a safety default to ensure the driver can see (via defroster) in the event the electrical has an issue. This ocurres when someone works on the vehicle w/o disconnecting the battery. Will need re-flashed by the dealer or someone in the know.
Check to see if you can still turn the hub lock outs by hand (if app) My guess would be not. They probably need to be replaced or taken apart and re-greased.
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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