Seems to be an ongoing problem with controls and vents. I've searched and read other posts but can't seem to find the answers directly related to these issues.

2002 ZR2 manual HVAC controls.
1. Had fluid in controls and ran down on/in ash tray.
2. Replaced transfer case switch, dash control switch, flushed vacuum line and blew out to clean out fluid.
3. Put back together and all seemed ok except for "hot foot".
4. Everything seemed fine.
5. Now, over a year later, I guess I'm just noticing it more, AC works better at times than others. I would hear some type of click coming from the left side of dash vent and AC would get a lot cooler. This was back from the summer. Or I could turn the controls to off and back on and the air would get cooler.
6. Now I'm experiencing some hot air from the dash vents and some comes out the defroster vents and gives me a "hot" face. I can close off the dash vents and it makes the defrost vents a little worse. Heater control is set to blow out at the bottom.
7. There is no hissing at the controls, for most parts all works fine according to the controls setting.
8. Do I need to clean or replace some actuators that operate these devices or ??

 

Clicking behind the glove box with an associated change in temperature output from the hvac system is a classic sign of a cracked gear in the blend door actuator (electronic actuator that sits on top of the hvac housing to move the blend door which controls air flow over the heater & a/c cores.

As far as the output locations, that sounds like fluid could be floating around in the actuators. It is EXTREMELY difficult to get the system cleaned properly.

Also, if you only replaced the vacuum switch on the transfer case, the problem may be reoccurring. The underlying issue most likely wasn't fixed and that is a leak in the input seal on the front of the transfer case. To confirm, pull the fill plug on the back of the transfer case. If fluid pours out, the input seal is bad and is allowing the transmission to push fluid into the transfer case.

 

Since it's going to be warm this weekend plus I have Friday off, I'll do some investigations starting with T-case fluid. I'll update findings. Thanks Swartlkk!