Servo motors seems to work

Ok, I checked for movement when I changed vent settings, floor, cabin, defrost etc. Everything moved when I changed settings and from hot to cold. I replaced blower motor resistor and now all my fan speeds work. But I still only have heat coming mainly from defrost setting, all other positions barely blow are no matter what speed...
Whats going on?

 

Have you checked your cabin air filter?

 

Yep, wasn't even one in it, but I put a new one in

 

Next I would verify the blower is rotating the correct direction, if it is and your actuators are working then it's likely a dirty evaporator or broken blend door.

 

How would you even begin to get to the blend door? I can't even see the vents and where they go with a light.

 

Take the actuator off and rotate the door by hand with the blower on, you should be able to hear the air change if its still intact.

 

OP, there are several air control flaps inside the HVAC box that are covered with foam. There was an issue on some 2007-2009 models where the adhesive holding the foam would fail and the foam dislodge and block air flow. Here is a TSB from 2009 that may relate to your problem I had the issue on my 2009 and was able to replace that flap without dismantling the entire HVAC box.

TSB-heaterdamper.pdf

 

What did you take apart to replace that flap??

 

Well, there is no way around it if you try to repair anything inside the HVAC box you will have to remove the dash. My failure was down inside that central defrost vent up against the windshield, but yours could be on another flap. The FSM wants you to do even more extensive surgery to remove that defroster piece because there are two bolts on that big nozzle piece on its reverse side up against the firewall that are near impossible to get to.

I ended up making 4 vertical but narrow cuts in the sheet metal of the FW behind that piece and then using a long 1/4" drive extension to remove them. But someone a bit more creative about fashioning tools may be able to do it without those cuts.