rdean said:
(snip) I had this issue once before, but the dealer fixed it under warrenty. (snip)
__. An unfortunately frequent scenario ... "the dealer fixed it, now it's broken again and I have to pay to fix it". Too bad, we feel your pain, brother.
__. But, to get to your problem, if you don't have re-circ on, there's plenty of air out of the dash vents (when the rotary switch is in the dash setting)? Is there good airflow (when I say good, I mean reasonably good - it's never going to be like with the fan on) with re-circ off and no fan when you're driving at highway speeds? Does the defroster work well on both fan-on and fan-off at highway speeds (again, there will be a lot less airflow with the fan off but there should be a reasonable amount of airflow with no fan)?
__. Just guessing, it sounds as if the re-circ flap is either loose or not being actuated properly. But usually if it's loose (this is usually because a hinge pivot has broken, worn or come loose), the flap jams and won't release at all and that screws up both re-circ and outside air flow. I dunno if VW's use cables to pull that flap open and closed (some cars use air/vacuum) but whatever, it's a PITA to get to and fix. Since the flap seems to be moving (although it seems to be moving to an incorrect place), the linkage probably isn't loose entirely but there's something about the actuation of that re-circ flap that's wrong. Maybe it's adjusted wrong, maybe the linkage is partially loose, maybe it's the flap itself.
__. I just replaced the blower motor but I've never had to deal with this kind of problem on a VW. Maybe someone with experience can help you.