Ive had to replace a number of control heads in the past so it is possible to be that too, but it is much much less common. I dont know the price of the manual control head but I know some of the EATC control heads can cost over 600.00, so I would make sure that is the problem.
Just replaced the Manual Air Temp Control with one off of an 08 XLT at the junkyard for 30 bucks. I figured it was worth a try, but no dice. Just got back from a trip and it did it again. Like it was fine one minute then it goes skitso. So it must be blend door issues or some other weird electrical problem = I'll just live with it.
I had the same problem with my 04, i couldn't get good heat unless it was on 90 from my control panel, and my temp gauge oon my dash was going crazy I replaced the temp sensor behind the grill on the center support and it took care of the problem.
A/C was stuck all the way cold. I replaced the blend door actuator this morning and it's working great again! 2007, F-150 Lariat with digital climate control. Doorman model #604-218 from AutoZone, $30. I used the 8mm wrench in the picture to remove all 3 screws and did not need to remove the passenger airbag. Those 3 screws are the hardest part of the job. If you have George Foreman-sized hands, you'll need to get someone else to help.
Update 5/29/14. The Dorman part made a loud clicking noise when it reached the high and low limits. I bought the one from the Ford dealer, 9L3Z-19E616-E, for $50. It is quiet through the full range of motion and the system works great.
View from radio opening:
View from glove box opening:
Last edited by P-Bod; 05-29-2014 at 08:28 AM.
Reason: Updated repair