It's either faulty (or the old servo is) or you aren't pushing hard enough.
You got another 25t servo around to try (other than the one you took out)?
You could just get a normal servo horn with no saver, but i'm pretty sure you'll toast your servo fairly quickly. And it'll probably be exactly the same size as your current horn.
And FWIW, i chop and change servo horns and servos all the time, no issues. Except for one which had 26t. Everything else has 25t
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