Hi,
What you described sounds like it is related to what is called the mode door actuator. This actuator is responsible for air flow direction. It could be stuck between the settings.
On this vehicle, there are two mode door actuators, one for the defroster and the other for the floor and panel vents.
I attached the directions below for the removal and replacement of both. What I suggest is this. Remove one at a time and inspect the gears on it first. If they are good, then with it plugged in, see if it reacts when you change the air flow direction.
Let me know what you find.
Joe
See pics below.
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Sunday, January 22nd, 2023 AT 8:40 PM