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Have you ever driven with anything on the dash? There is a very good chance that something as simple as some coins or a pen or pencil has fallen down the defrost vent and the object is blocking movement of the blend door or selector. Can you take a look with a mirror perhaps? The best way to look would be with a boroscope but I doubt you would have easy access to one. Good luck. You might be able to confirm if there is an object in there by knocking on the heater box under the dash with the knob in an unstuck position and listen if you can hear something bouncing around inside.
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Rick "C.O.B" (Crusty Old B.. boy, barnacle, whatever)  
My system:Cool Master 532 case and Seasonic S12-600w PSU, Asus A8N32-SLI Deluxe MoBo, AMD Opteron 180 Denmark 2.4GHz Dual-Core CPU, Seagate 1Tb SATA II "C" Drive, w/2 Apricorn External HDD cases loaded w/ Seagate 250GB HDD each as backup drives, BFG Geforce 7800GTX 256MB PCI Express x16 GPU, CORSAIR Twinx2048-3200c2pt 1GBx2 memory, and a LG Electronics DVD/CD burner in Black.
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