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the flapper inside the das is probablay no good I forget what its actually called but its basically a big flapper that rotates around to change the direction in which air blows and which vents are used, something could be causing it to malfunction and not reach the dash board, you can check the power to it with a voltmeter and check to make sure when you turn the switch on the panel from floor, to vent to dash you chack that the voltage is changing and acting appropriately with what you do on the panel, this eliminates the possibility of the switch being bad...
1 could be the switch....
2 could be the flapper
3 could a power issue to either component
4 could be some type of relay/maxi fuse for it ( less likely )

This is a great place to start I would be very surprised if this does not help, however unless you've done all this..

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