I recently noticed that no matter what setting I have the HVAC on, the dash vents are always getting air. The other setting will blow air too, but the do so along with the dash vents. This makes for weak air flow to where I want it, thus using fan speed 4 and 5 to cool the car with the A/C. I've never used above fan speed 3.
I have a brand new HVAC controller (dual zone), and I've re-installed my old one with the same symptoms. I'm guessing it is one of the actuators? Or is there another component that controls the vent location?