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Lee,
I think there are a number of potential sources of backlash:
1. Mesh between worm and ring gear
2. End play in the worm (ie longitudinal movement of the worm between the worm bearings).
3. Belt too loose
4. Belt gears not locked on worm/motor shaft
If you've eliminated 2,3 and 4 and are having problems getting the mesh tight enough without the axis binding, I think you are experiencing run-out in the ring gear. This is common on these mounts and is a manufacturing tolerance issue. I think the remedy is hobbing the ring gear however I believe this is not a simple exercise.
The dec axis does not make a full rotation in normal operation and if the polar alignment is good it barely moves at all. On mine, I set the worm mesh at the tightest point so it never binds. There are dec backlash settings in EQMOD and I think newer versions of PHD2 are also trying to measure and compensate for this.
Peter
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