Rear blend door actuator problems!!!!!

[Bizmarck5425]

I have a stock 2004 ford explorer xlt. The problem I am having is with the rear blend door, it was making a loud clicking so I did some research and wrench turning and found gears to be stripped in the actuator for the blend door. Got the OEM replacement from ford but when I try to install it it does not seem to work properyl, I.E. the actuator seems to have more range of motion then the blend door can physically move. I can move the blend door manually and it seems to be free of obstructions(all the way down gives me full cool and all the way up gives me full heat). Now when I first started the replacement I set the blend door to full cool turn the temp knob to full cool, plugged in the actuator, then turned the car on. I was told this would set everything in the correct position, but when I slide the actuator in the blend door peg it is ****ed off the screw holes about 15 degrees. It also seems that if I were to mount it and turn the knob it binds at full heat and full cool. Any ideas or solutions would be greatly appreciated.

 

[Bizmarck5425]

I also took the actuator apart and watched it move and it seems to not know where to start and stop. If I turn it full cold it continues to try and turn even after the gear with the arm is at it's full extent. Leads me to believe that is why the first one had stripped gears

 

[Bizmarck5425]

Really no one has any insight? No similar problems? Anything?