Symptom returned. No heat unless raised upto high temp. Some days it works and some days very little heat. I ran the vehicle with radiator cap off, full heat, front wheels raised for 20 min. The return hose is connected and the sensor is clean as well. What's next?
Plugged heater core is my mechanic friend's guess?
How difficult is the core replacement? Its 2004 with 130k. Thanks.
You can download a copy of the '04 FSM...check the FAQ section for a link.
Looks to me like about a 19-

job, assuming no beer when you begin. Though maybe half a case when you're done.
Before I went to the work of evacuating the A/C, removing the instrument panel and its reinforcement, and both the cooling box and heater core boxes from the interior, I'd drain a quart or 2 or coolant, remove the heater hoses at the firewall, and check for core blockage.
Since the coolant flows through the core all the time, my opinion

would be to check the operation of the moveable doors in the heater/A/C box. FSM will tell you how to put the truck in diagnostic mode. Simple.
I'd avoid pulling the heater core unless, obviously, you're seeing no coolant flow through it.
As point of reference, my '01 LX gives me tons of heat after driving about 1-1/2 miles with outside air temp around 20F.
hth
Steve