i suppose that isnt under warranty anymore? this is going to suck.
there are flaps actuated by servo motors at certain junction points in the AC ducting, or perhaps all in one master junction box that all the ducting runs through. i think that's how it is on my 2000 4.6. Anyway... each servo motor is connected to 1 or more flaps by gears or some kind of linkage. if that linkage breaks or gears strip teeth, then they won't open and close the flaps successfully. this results in the flaps being stuck in one position - sending air only to the feet for instance, despite indication from the system that you have directed flow to the face. in my 2000 (gen II) range rover, when this problem occurs sometimes the system will be nice enough to display a little warning triangle in the HVAC display. do you have anything like that being displayed?
you may be able to hear the motor turning the gears or actuating the linkage unsucessfully. you would be listening for a clicking noise coming from back inside the dashboard (not sure exactly where on a gen iii range rover).
do this: change the system to heat, and direct the flow to the feet, make sure the fan speed is low so you can hear. do you hear any clicking noises? now change flow to the face. again do you hear clicking noises? try this with both cold air and hot air. i do not know how the 04 AC system valves work, but it might be significant if you discovered heat works fine blowing to both feet and face, but AC only will blow to the feet...
if you do have 1 or more of those bastards to fix, and its not under warranty, labor will be the issue. some portion or all of the dashboard will have to come out to get to them. you posted this on the sport/p-38/gen iii forum? maybe somebody knows about a recall or some other way to get this remedied without shelling out a ton of $$$.
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Pat Herman
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