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I have an 2004 Aviator, im having similar problems, i took it to the dealer for a diagnostic, and they did the dirty work for me, either your blend door actuator is bad or the actual blend door which redirects air from the cabin or fresh air from the outside is broke and it staying in one position, making it incapable of switching modes to control the direction of the air, Ha Ha Ha the dealer quote me 975.00 dollars for this job, they say the actuator and the blend door are only approximately 100.00 dollars for parts and the remainding 900.00 are for labor, [violative content deleted], well i doont think so, im gonna reoplace these parts myself , if ur mechanically inclined u can do it in approximately 5 hours or so, but off course the dealer is out to make money from you and they say its a 9 hour job, so they will take their sweet ass time if u know what i mean, me i will get a Chilston manual, remove the dash, remove the evaporator, and replace the door or the actuator which ever is bad? i will take pictures and post in a couple weeks, i hope thios helps, this days u got to save every penny, good luck....
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