Drivers side no air conditioning

There are two blend door actuators, which did you replace?
Did you initialize the actuator after replacement?
Disconnect the battery, turn the temperatures to high then reconnect the battery and turn on the key to the run position, does not start the car. After thirty seconds the initialization should complete. Test operation of the system.

Be advised this will also reset the learned idle speed so it will need to relearn that as well.

Once installed the unit should calibrate to the correct position, it basically just runs the motor back/forth to the stops on the doors and that way it knows the entire range. The reason I asked about which one is that there are two temperature actuators, one mounted under the HVAC box in the passenger foot well and the other on the side of the case above the drivers side.

Good to hear, please use 2CarPros anytime we are here to help.

Cheers, Ken

That was the one above the drivers side footwell correct?
The passenger side works correctly?
If those are correct then it almost has to be a broken door itself, either the axle or the door isn't in the correct place.
First, turn on the AC and watch the actuator you installed as you change the drivers side temperature, does anything move?

Remove the actuator you installed. Turn on the AC and see if you moving the shaft itself with some pliers changes the air temperature.
If it does the door is OK, if it doesn't the door is broken.

If it does work then there is an issue with the actuator or the control head. You said you moved the new actuator to get it to mesh. It's possible that damaged it, they are usually cheap plastic gears inside the housing.

To test it and see if the unit has any fault codes you really need a dealer level scan tool that will let you "talk" to the controller.

The shaft the gear is attached to, it moves the door inside the HVAC housing.

Very fine material sounds like the foam they use for the door seals.

Here is a test you can do, it goes with the images added. It runs the actuators through a test cycle and might let you see what works better.

Image 1 here

a Turn the ignition switch on (IG) while pressing the FRONT DEF switch and FAN+ switch simultaneously.
B Press the R/F (Recirculation / Fresh) switch.
C As each damper, motor and relay automatically operate the actuator check at 1 second intervals from step No.1 to No.10 continuously check the temperature and air flow visually and by hand.

Image 2 here

d If a slower display is desired, press the driver temperature up (UPDr) switch and change the display in the step operation. Each time the driver temperature up (UPDr) switch is pressed, the display changes by 1 step.

HINT:

The buzzer sounds when the displayed trouble code changes.
Codes are displayed from the smaller to the larger numbers in order.

Image 3 here

e To cancel the check mode, press the "OFF" switch.

Another test you could try involves removing the drivers side unit and the passenger side and swapping the actual actuator units. They are the same, it is the gears that make them different and those pop free if you move the tab that retains them. Reinstall and see which one(s) work.

Here is a actuator diagram to help us see whats going on and to make sure we are all on the same page.

It sounds a little expensive what do they is wrong?