Posted this not long ago, but no replies. So I'm going to change this thread a bit.
This is becoming an issue with colder weather peeking in with this defrost issue, I'm only able to use vent to heat or cool. Not able to use the defrost or floor switch. Thanks to this forum, apparently it's the blend door actuator.

Called the dealer and they wanted $800 to replace the blend door actuator. Gee! They said it's labor intensed, also said probably foam is stuck, and actuator part might not be needed. If I decided to go with dealer to do it, should I have them replace actuator anyway since they are prone with problems in this generation?
Has any one of you done the work on it, if so how was it? I'm hoping doing it myself, should I invest a good manual for it? Which manual is recommended?

 

Dilas the work has been done. There is a way to get to the side of the blend door through the driver's side footwell area. I'm surfing via my phone right now, otherwise I'd run a search for you. There is a thread or two detailing how to get in to reach the door.

 

Did the job on my wife's Windstar and it was pretty easy. The biggest issue was the cramped quarters. I got the best price for the actuator on Amazon.

 

You meant this thread?

https://www.ford-trucks.com/forums/8...procedure.html

Seems like it's on passenger side instead of driver's?

 

You got it!
Now lets just hope that I didn't do all of my jobs yesterday from the wrong side...