Blend door actuator clicking after being replaced

Hi All, haven't been able to find an answer to this so created this topic. My girlfriend has a USDM Ford Fiesta 2017 (MK6) and for some time there was a loud clicking sound under the steering wheel, especially when the car was first started with the AC on. I found this video which explains what and where and had the same exact noise, so I ordered the piece with code be8z19e616a from a local parts shop and it showed up as a genuine Ford part. However it was just the shell and the plastic gears inside, without the PCB, so after disassembling the original one I only found a small piece of the white plastic gear that had broken off, which seemed strange as in every video/post that I found about this issue large chunks were apparently missing. Nonetheless I replaced the PCB in the new unit and installed it and to our great joy it didn't make a single noise. Joy didn't last long though as after a few days the clicking came back, but usually not after starting the car, but after some time. So I removed it and it all seems fine inside. I even assumed that maybe the passenger side one was broken, so installed the original one in there, but I can feel the one under the steering wheel clicking. I even tried to orient it in a few ways, probably spent 2 hours installing, removing, clocking it differently, etc. To me it seems like it rotates to the very end and doesn't stop, just keeps going and that's what's causing that noise. Forgot to mentioned that when the issue first appeared the blend door worked fine, both cool and hot air coming out and could set it at different places.

So the final piece that I can think of is the PCB itself that was reused, but visually nothing looks burnt. Has anyone run into a similar issue where the PCB is bad and needs replacing? At this point I'm considering just going to a junkyard and pulling a unit out of there to just validate it.