USUALLY its a vacuum problem, look for a vac line off around the right side of thef irewall. I say USUALLY becauseI 'm not familiar enough with your model and it may have all electric motors for defrost.
Inside the venting is a flap that is controlled by a vacuum operated actuator. This vacuu hose also runs to your control panel.. Either the vent is stuck, the actuator is faulty, or there is a bad/leaky vacuum hose
This problem sounds similar to the problem I had on my 2002 Ford Explorer. The vent control would not change the vent direction from front to defrost and such. Turns out the Vent Control Box control arm is made of plastic and broke so that it was no longer connected to the vacuum motor. You can easily determine if this is the case. Open the glove box and empty all of its contents. Then press in the sides of the glove box until it can be moved rearward and down. Look in the space behind the vent controls to see if the plastic vent control arm is connected to the metal vacuum motor arm. If not that is your problem. You may need to start the engine and move the vent control selector to see the vacuum motor arm move. It will move whether or not it is connected to the plastic arm. A dealer will charge $2000 for this repair because they will need to replace the entire vent box assembly. I fixed mine for next to nothing. I will share if anyone is interested. Note: The repair is simple but not easy as there is limited space to work and you can only get in there with one hand. Warning: There are really sharp metal brackets in there that will cut you if not careful. See image for the fix,
SOURCE: 2002 Ford Explorer When turned to defrost air
sounds like your door blend actuator which is under the dash and a pain to replace
SOURCE: my 2002 ford explorer wont blow any air out of the vents...
It sounds like blower motor has failed. Motor is located behind glove box on lower part of heater box.
SOURCE: 2002 explorer a/c blowing out of defrost and not dash vents
The direction of the air flow (dash/defrost/floor, etc) is controlled by vacuum going to the switch. There may be a vac line that didn't get connected or was damaged when they put the replacement engine in it. Check the lines on the firewall to make sure nothing is loose.
SOURCE: a/c blows out defroster vents
Airflow goes into one main duct in dash and is redirected to the appropriate vents selected by the fan control switch on your dash. The shutter is controlled by cable attached to the back of the climate control unit. The problem, if the shutter or control switch, should be the same regardless of AC or Heat selection. The shutter is either stuck open or the cable has broken to control it. If the fan direction control switch is hard to turn and offers resistance or just the opposite it has too much free-play the cable is the culprit and is stuck or broken. If there is resistance it could be the shutter stuck and its within the dash. that is a bit more intricate to get fixed as you have to access the shutter by removing the dash.
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