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I did some playing around with mine while I had it apart doing the hot knife hack. I don't think actuator is the sole reason these blend doors break, I have no doubt it could contribute I just don't think it's the lone culprit here.
Once I got the new blend door in and duct all reinstalled I turned the key on and ran the fan speed up and down before I attached the actuator. I could not hold the blend door shaft in one place (at any partial setting) with my fingers past about 50% fan speed. With it at 100% I felt I was going to damage the shaft with pliers trying to hold it in place.
Mine wasn't completely broken but was cracking at the base of the actuator shaft. So it didn't have long before it failed. Turned out my real problem cooling at the time was a leaking high pressure service port.
As a result I now keep mine below max on the cooling for the actuator theory, and rarely turn the fan past 75% based on my own findings.
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