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Sound's like you have nearly the same issue as me. My truck blows to the floor and the windshield, but not the front vents. The issue comes from the air diverter door. the hinge has broken off where the vacuum pump arm is connected. This is not fixable unless you remove the whole heater and A/C box from the vehicle and take it apart which would require disconnecting the R-134a & heater hoses from the firewall/bulkhead.

Easiest solution is to remove the steering column and dash and fixate the door in such a way to permanently select which vent the air is directed. On my truck, the heater core has gone bad and it's not worth replacing. So I have fixed the door to blow the air only out the front vents for in the summer when the A/C will be running.

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Q: Why would a 2004 Dodge Dakota not blow air to the defrost but blow air to the floor and front?
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