The vehicle is a 04 cav with a/c.... I did a search and could only find issues with the speed selector.... we have good flow on all the settings... but the problem is... when you select the first 2 settings for the front vents (a/c) there is very very little air flow out of the vents..... could this be a problem with the switch itself??? any advice??

I have all sorts of weird problems with the HVAC system on my '05. Most stem from the air diverter/select door motor. The door probably isn't going fully into the position until you hit the high speed on the blower and the air forces the door into the selected position. There's a hell of a lot of work involved in taking the unit out for repair and I haven't been able to have my car out of service for long enough to justify repairing the problem. If the door is stuck then you might need a new select door motor or possibly even an entire select door assembly. If you bring it to a shop for repairs, expect at least 3 hours to diagnose and another 2 for repair + parts.

hmm so it cannot be as simple as a bad switch?

I was just looking through the book. The pinpoint tests are pretty straightforward for the switch and the selector. It's pretty much either they work or they don't. A lot of it is controlled by the Body Control Module which grounds battery voltage to make these things work. It should be either hardware (like I stated above) or possibly a wiring issue. If the motor isn't getting enough battery voltage, it might not have enough torque to move the blend door.

sounds good... will def look into this once my brother brings the car back up here...

Just for the heck of it I would check your blower motor resistor.

that's what I figured as well.... but not getting any of the usual symptoms...

i have a simliar problem... but only when the car is off... the vent selectors don't want to change... as soon as it starts up it'll be fine...

as long as it works while the car is running, i'm not worried about it... the "black box" is a pain to tear out