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My work ute is a 2004 Ford Falcon. I recently had the dash out to chase the same issue of no heat and discovered the usual suspect of broken control rod was actually not broken, and the flap was ok.
After having the module open and greased the internals, we put it back in, all clean and fresh with the new Aerpro ICC and it was great until it wasn't again.
A seemingly bad connection at the motor has been corrected and now I have heat control again. Ready for Winter.