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These trucks use a small electric motor to control the blend doors. You may have a door that is sticking or a motor that is binding up. You'll need to remove the motor assembly and take a look.
I am not an expert of Volvo's but what you describe is normal operation for most cars. If hot air was directed at a very cold windshield it could crack it. So when you kick it over to defrost, the hot air is mixed with AC air and the amount of air flow is restricted so that it doesn't crack.
Did the operation of your Volvo defrost system seem to change all of a sudden and that is the reason you posted this? If so how did it change?
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