What you are experencing is common for Ford light trucks( Explorer, Ranger). The blend door actuater has a square peg that mates with a socket in the blend door itself. Over time, the plastic socket on the door becomes brittle and cracks, thus no longer mating with the peg.
I have repaired several doors by accessing the blend door and the broken piece( it doesn't go far, it's traped in the HVAC box) and using epoxy and two very small zip ties. You will have to drill two small holes for the ties.
Unfortunatly the HVAC box is accessed by removing the instrument panel( dash board)