Most of these components are located way up under the dash and may require removal of the entire dash to gain access. Any vacuum leak can cause this problem, as can a bad vacuum check valve, so check all lines using a vacuum gauge before you tear into it.
SOURCE: 2004 Ford Crown Victoria no air flow through main air vents
Chances are the electronic/digital HVAC control unit is bad. This same problem happened to me and I had to replace the entire unit. The dealer wanted to charge $800 for just the part! After I freaked out on them, they found a used one for less than half. Sorry, but there's no easy fix here.
SOURCE: There is no air flow
You need part GM Part number 89018675 or ACDelco 15-73596. The Mode Selector Actuator. What happens is the part is a CHEAP part POORLY designed and when it goes to turn the flaps inside the HVAC unit its the plastic gear slips instead of turning the flap!!!
Just to forward you you might want a deal to install this art for you unless your good at fixing your own vehicle, because you need SMALL sockets and a lot of patience to get this part in!!!
The part is ALMOST directly above the steering shaft for your steering wheel, so theres a lot you got to remove before you will even see them!!!
I only recommend you to have a dealer put this part in for you, unless you have your own service manual!!
Because there is 5 of these darn things and if you pick the wrong one you will have to do it all over again!!!
3 on the Drivers side and 2 on the Passengers side!!
But replacing this part SHOULD solve all your problems!! AS it did for me and i was having the same issues as you have described!!
SOURCE: HVAC vent selector does not function. Air flow is
THe blend door seems to be stuck. When you change settings from defrost to floor air or, vent, the blend door opens and closes directing the air to the place you want it to go to. I have had some success spraying a lubricating oil such as WD40 under the dash on the blend door. You need to get under the dash with a flashlight to locate it. It looks like a flap. Spray it with a couple of shots of the WD40. Go easy on the spraying as you may be inhaling the fumes. Keep the doors and windows open to minimize the fumes. Wait about 1/2 hour and try the A/C functions. (defrost, floor, vent air)
SOURCE: PROBLEM WHEN SELECTING THE DIRECTION FOR THE AIR
Sounds like you have a supply vacuum problem. When you lose supply vacuum to the control head it defaults to defrost.
SOURCE: AIR FLOW STUCK IN DEFORST VENT WILL NOT SWITCH TO FLOOR OR AC VEN
The "MODE" door works off of an electric motor.
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