When i removed the heater box the first time, there was no foam around the heater core pipes nor was there any sign that there ever was, but i suppose now that ive disturbed it it could not be sealing that part of the box against the firewall, like it was before.
All doors are working correctly, and the seals on my doors are all rubber and sealing properly, as far as i can see. As for rod #153 I put it back on the same place it came off, and air valve #163 will only go back into the heater box one way, and it moves with air valve #171 (rod#153 hooks the two together), and is directing air in the proper direction when set to either deforst, heat, or vent. Seals #170 are all in place as I never had to move them or anything when I changed the heater core.
But now that we have a picture when I say I have heat out of the top 3/4 of the vent hole its the rectangular hole between numbers 162 and 164 and the air valve #163 is directing air through that hole and like i said the top two holes in that valve are blowing hot air and the bottom is blowing cold outside air.
Im thinking im going to remove the heater box again, and see where excatly the new foam I installed is sealing against the firewall, run some foam around the heater core pipes, and pull the heater core out of the heater box and hook it up to the heater hoses and run the truck and then i can feel exactly what part is heating up and whats not if the heater core really is partially restricted, and then go from there.
Im at home right now and wont be able to try this till monday after work, so ill let you know what results I get back