Was the part an AC Delco? If not, this is your problem, I know the original went out, but these parts are cheap, and the aftermarket ones are even cheaper. Or you could have an obstruction inside the plenum such as a pen or stick that has failing inside the vent system and is causing blend door not to operate on its full swing. I would remove the actuator and try to turn the pivot by hand, you should hear the blend door open and close fully.
Check out this guide which shows what I am talking about:
https://www.2carpros.com/articles/replace-blend-door-motor
I have included instructions in the images below for proper installation.
Check out the diagrams (below). Let us know what happens and please upload pictures or videos of the problem.
Images (Click to make bigger)
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Friday, August 19th, 2022 AT 9:28 AM