I was speaking to the OP. I didn't indulge myself into your links you posted.
You def sound like you have an issue if it's sporadic, but for the OP. I still stand with statement that HIS truck is normal. Most guys only notice the terrible output on super hot days or when they have another(diff brand) vehicle to compare theirs to. Most problems like this guys have always had but never noticed until it's "inconvenient" for lack of better word...for them.
You sound like you have both blend door and elect. problems.

 

I just ran into the problem of no air coming out the vents no matter what speeds or settings after I swapped out my engine and went to put on the defrost. Turns out the recirc door busted off and fell right on top of the blower moter. The air is not enough to move the door out of the way to let air flow through. The mode 1 and 2 doors still work. I had dropped the blower motor to verify it still works and it did. Then I reached my hand up above where the blower motor blows air and the first thing i hit was my broken recirc door. I tipped it sideways and pulled it out, and put the blower back in and boom, I have air flow again and everything is working. I still have to get the new door and put it in but at least I have my defrost and vents blowing air again.

 

That is the exact same thing that happened to me. However I have heard/read that if you buy another door from dodge, that it will most likely break also. I may just leave it off.

 

Same here. Last week I noticed it took 30 miles out of a 65-mile commute to cool the truck down. Came home, pulled teh glovebox, dropped the blower, stuck my hand up and.....there was that damned recirc door....laying right over the blower.

Ten minutes from start to finish and thankfully I have good, strong A/C flow. And Bubba870 is right; use a nutdriver.

 

So you guys pull out the blend door and what functions do you loose?

 

The one we removed is the Reciculation door. The Recirculation door is the one that breaks and falls over the blower motor, severly cutting down on the amount of air comming out of the vents. If its sounds like a tornado behind the dash but only a little air is comming out that is the problem. Basically if you remove it you loose the ability to have only outside air or only inside air conditioned.


If your blend door/s are broken (there are more than one) than you won't be able to change from feet to defrost and such. Hence, people complain that they can't defrost their windsheild.

 

the blend air doors only control the temperature they are attached to the same actuator (in a single zone) (dual zone the blend air doors are ran by seperate actuators) and cover the heater core those doors are directly behind the glovebox i believe you are talking about the mod 1 and 2 doors which control the defrost and feet and panel

 

i havent tried to defog my windshield, but before i ripped the door out, it wasnt blowing enough to clear the window

 

I had the same problem with my 04 1500 Hemi. I searched the internet for a solution. I came across this site and read all the other Ram owners having the same problem. I removed my blower and guess what? Lying on top of the blower was the broken recirc door. I removed it and the thing is blowing up a storm. It only took 10 min to take it off and put it back on. I would have spent a fortune getting a pro to fix it if I had not found this forum. Thanks all of you for your help. God bless.

 

Just a heads up, I have found many rodent nests in blower motor housings

and vents.... Keep your face away when you pull on stuff.