Hmm... Have you checked with a local store that sells truck parts/accessories. That might be a good way to go without having to replace the entire thing. Saving you money in the long run if you can do a quick fix.
It looks like it's in great shape. Why fix something if it's not broken. But a few details can't hurt sometimes. Up to you, but I think it looks great as is
There has to be an issue with the controls and how the air is diverted obviously. Not sure what else to do in the situation since you said you took apart and replaced the control unit. Is there anyway you can inspect the hoses and the vents leading into your cabin and see if something is at...
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