Servo Problem

[WAM]

So I'm in the middle of testing this thing, but thought I'd ask for other's experiences so I don't totally reinvent the wheel. I've experienced my third servo problem an about 4-5 comps. The first two were Hitec 7950s and seemed legitimate failures. The first has already been returned from warranty and they replaced the motor.

But having so many problems, I have to wonder if something else is going on. Having lost two 7950's I was down to my 7954 spare which is about the same animal except "metal" gears instead of Ti. On the fourth gate of the first course I started getting steering refusal. Just wouldn't try very hard to turn. It was warm, but just barely. I picked it up and set it on a flat rock (5lb sporty) and it wouldn't work the tires back and forth.

So last night I got it on the work bench and crap -- now it feels normal. Called Hitec and they don't know. They say when they get too hot to touch the motor may lose about 25%. Mine lost at least 75% without getting more than barely warm. I asked for a safe testing procedure and he said I could lift a 5 lb weight off the floor on a 1" arm. My "bad" servo currently does that easily. I also checked voltage at the RX power bus and it read 7.38V. Fine since I set it at 7.4V. I next need to make up some test cables so I can check voltage under load, and maybe do some duration testing to get some temperature into it.

I hate intermittents. So hard to track down what's happening. Anyone had similar experiences and figured it out? I think I've previously noticed occasional marginal steering force from time to time, but not this bad.

[KBrog]

Lets get the simple stuff out of the way first.

B.E.C.?

EPA's set correctly?

No binding in the steering linkage?

[WAM]

yes/yes/no

My other warranty 7950 came in today. They said defective motor, but replaced the IC's. Maybe they meant both.
Gotta say...nothing wrong with their customer service.