Texas Classic XJ

Well I'll have to wait till my next day off and try fixing that gap in the foam to see if that will fix my problem. With my luck that's probably all it was.
Is there air suppose to be coming out of the defrost/demist vents that point at the passenger and driver window all the time? My car doesn't do that, so don't know if it's different on a Jeep.

Texas Classic XJ

I would check that foam piece around your defrost door and make sure there's no gap in it. And of course see if your defrost door is working. I think you might be able to see the defrost actuator( a little bit) with out moving the dash if you look with kick panel removed and looking up under there. Might be able to see if it's moving. If I ever figure out what's the 100% sure cause of this problem will defiantly post my findings.
I think the reason I'm having air coming out of the top dash defrost vent is the gap in that foam is allowing the air to escape into the top dash defrost vent duct.

CCKen

Refer to the vacuum circuit chart.

Air should come out of the outlet for the windshield and the demist outlets to the side windows when position 6 and position 5 are selected. Except that in position 6 you'll get air out of the floor outlets as well.

Texas Classic XJ

Oh okay, so then should there be some door/flap on the hole next to the defrost door that blows out to the demist ducts?
Also everything seems to work properly based on what mode I select. I think the reason I have air coming out of the windshield defrost vent is because of that gap in the foam piece. I noticed the other day after playing around with it that you hardly feel air on the driver side of the windshield defrost vent and that most of the air comes out on the side towards the passenger. Which is why my guess is that stream of air leaking through the gap in the foam. The only thing I'm still confused about is the duct next to the windshield defrost duct that goes to the demist vents has no door or something to keep air from going to the demist vents when not selected. Though there is a door for the duct going to the windshield defrost vent. Sorry if that's confusing.

freegdr

Is that not where the fresh / reculate air comes in doors on bottom .

CCKen

That outlet has no dedicated door. There are only two doors involved, each door has baffles that direct the airflow when they are open and closed. You should be able to see these doors in action and note the position of the baffles when cycling the mode selector through the various positions.

If all the doors work when you cycle the mode selector through all the settings then I would suspect that breach in the foam is your problem.

Take lots of photos of what you have opened up and post them when you figure out how to post pics on the forum. I use Photobucket http://photobucket.com/ which works pretty good for me. It’s a little hard to get used to when figuring out how to copy an image url and paste it to a post, but once figured out it’s a snap.

You can also use Flickr as a photo host. http://www.flickr.com/