Replacing Blend Door Actuator - Lining it Up [2004 2.7L]

I'm having trouble getting my new blend door actuator to correctly move the door arm/cable. I installed it, aligning the actuator pin with the door arm slot (had to adjust the door arm to get them aligned). In testing, the actuator functions (moves when the hot/cold knob is turned) and it *slightly* moves the door arm, but not enough to open/close the door.

Not knowing what I don't know, I figure I need to adjust where the two "meet" along the door arm travel pattern. But while I can manually move the door arm anywhere along its travel pattern I can't manually move the actuator arm/pin.

Clearly I'm doing something wrong so am hoping someone here can set me straight.

 

Man if you can
Post some pix of this clearance issue

 

In my “limited” experience…..
See if you can loosen/set back some of the surrounding components to get your clearance
Not taking off….just to wiggle the offending part to get clearance

 

I don't think there is any sort of "adjustment". When you turn the knob, do you hear the servo motor run smoothly and then start to strain and eventually stall out? If the heater valve cable is binding it won't allow the door to open. Do the both the blend door and the heater cable move smoothly without being attached to the servo?