I removed the rotary actuator from the left side of the air box after removing the glovebox. There are two screws holding it in. You will need a 1/4" drive ratchet with a 5.5mm socket for the lower screw and a 5.5mm offset box end wrench (easiest) for the upper. Warning: the upper screw will drive you nuts getting it out! It can't be seen but you can feel it. Up-plug the actuator by carefully un-latching the plug assembly with a small screwdriver. Remove the whole assembly. It just slides on the shaft that operates the door.
The problem is inside the actuator. The gears have weak teeth and have probably been stripped of a couple. GENTLY pry the actuator open. There are several assembly snaps that you'll need to be careful not to break off or you will be gluing the halves back together as i did.
The large gear (final output gear) will be missing teeth. Remove it and index the gear 180 degrees re-engaging some fresh teeth to the driver (pinion) gear. If you're off a few teeth in either direction, It won't matter. The motor shuts off with a resistance switch during operation. Re assemble and you're good to go. (At least until they wear out). I saved about $300 over having the dealer replace the motor/actuator.
Eventually, the motor assembly will need replacing. But at least it's a DIY job. Still saving $$$.
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