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Has the blower motor been replaced? My experience is that the secondary market blowers do not work nearly as well as the OEM blower. I hope there is one out there that does work but I have not found it yet after three tries. For me, A/C and Defrost do not have the output needed to do the job. Using a relay is about the only alternative since max output with the newer motors is the equivalent of medium on the OEM blower.
Craig
Not cheap but if you still have the old one you could send it out for exchange for one that has been restored.
http://www.bmcuda.com/products.asp?cat=10