Colder Air From Defrost Vent Passenger Side

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"00 Limited

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I have a 2000 Limited, which makes it OBS. When you have Defrost selected (which activates the AC) and turn the temperature knob about 1/4 or more down from hot towards the cold, the air coming out of the passenger side of the vent up by the windshield gets very cold - with the knob at "noon" its about 40 degrees colder than the driver's side. The airbox & controller are both single zone. I've got the dash out & have everything hooked up so I can run the vehcile & watch everything operate, and all of the actuators are responding properly. With the temp knob all the way on hot, things are pretty equal on both sides.

Things I've done/checked:

It's not an air leak - the problem is the same moving or stopped, and the air leak TSB fix has been done.

I have takne the "last" air box out (the one with all the doors that direct the air to the vents, floor, etc) and the heater & evap cores are clean on both sides & the temp blend door seems to be operating as it should.

I've tried blocking off the back upper portion (towards the firewall) of the "last box" where the air from the AC evap would come in & it made some difference, but not much.

I tried putting blocking off parts of the top of the last box (under the plastic "duct" that distributes the air to force the air to mix longer before it came out & that didn't help much.

It seems that the cold air from the AC evap is coming into the "last box" and going straight up the vent rather than mixing with the not air from the heater core.

I'm looking for any ideas, no matter how crazy - I've stumped everyone I've asked, amd I'm missing my Tahoe! :banghead:

Thanks
 

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