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My A/C "leaks" into defrost mode even when I do not select it....and it then condenses outside on my windshield and I lose visibility. Problem started about 3 months ago....unprovoked. It happens whether there is high humidity outside or not.
Have heard of the battery disconnect possibility to solve the problem when it is just A/C related to reset an actuator. Was not sure if anyone had this issue and tried to solve in a similar manner.
All my info is at home but I remember that if you lose vacuum then the system diverts to defrost mode of air flow. Have you done anything to affect the vacuum line from the rear of the manifold?
Mine does that too, but it's not bad enough I worry about it. I just get a little moisture spot bottom center of the windshield. The different vents get selected with the controller so I suspect there is a gasket on the door that is damaged letting it leak. It'd likely require pulling the whole dash apart to get to it.
Do verify that your controller switches the air flow between the different vents.