[davester3500]

Is it just that one mode (splitting air between floor and windshield, and otherwise the air is directed properly?

 

[davester3500]

How exactly is it not working?

I also have an '04, just w manual controls, but your ducting setup should be the same.

With a flashlight (and maybe removing the duct section pointing down at the drivers legs), at the mode actuator & cam to see how it moves as the mode's are switched. If def works, and floor works, 1/2 def/1/2 floor is between those two points on the cam (so for def, the cam is turned to it's limit in one direction, floor is in the middle, for split the cam is between those two points).