Totally Stumped

[dagored11]

OK - somebody tell me I'm not going crazy. I'd been having a problem with the heating controls in my '02 XLT. When I moved the control that directs the hot/cold air, the air didn't seem to go where it's supposed to. If I had it on defrost the air came out the vents - and vice versa. I had the blend door replaced last weekend, and it may be a little better - The air seems to come out great from the defroster, and I guess the floor - but the air flow from the vents is minimal at best when directed both vent only and floor/vent. But, on occasion, the air flow out the vent seems to improve somewhat, but never with the force that it should. Even when I put on Max Air it's pitiful. I took the control panel off to check the plugs and I noticed air escaping from inside the dash area when I unplugged the controller. Could it be an air leak somewhere? At times I notice a "creaking" sound coming from the dash like something is trying to move or shift position, but nothing really improves. This is really a pain in the summer when I put on Max Air - the air flow is pathetic and the car doesn't cool very well.
My diatribe is over - any suggestions other than grab a beer and live with it??