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Doug, I've done everything you've suggested including running the servos unattached and Motor Stalled still comes up. There are no cables snagging, I've dropped the worm right down so it isn't touching the gear as well as releasing the clutches completely. I've swapped motors, cables, gearboxes, run DEC through RA and visa Versa, used the Dec motor in place of the RA motor, yet when it stalls and I remove the motor I can rotate the worm by hand with no difficulties at all. It has me totally stuffed. I believe that there is something electronic, possibly in the encoders or as Phil has suggested in the RA socket, but it's the repeatable positioning of the stall that's got me. As you suggest it sounds mechanical, but given everything I've tried I don't see how it can be.
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