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I agree it's absolutely inexcusable for the standard SB is trying to set.
That said, I think I made some progress today by centering the worm in the Declination as Sarah at SB suggested. The Declination isn't throwing up errors today. I've done 6 or 7 50 point+ T-Point calibrations, and the Declination hasn't given me any issues - previous the Declination axis would give the error but the mount would show it present in both axis (no idea why. I know it was in Declination because if I changed Declination to Track and RA to Balance, the mount would still give errors but not vice-versa).
The current consumption also seems a bit down today (approx 300 mA while slewing. It ranged form 300 mA to 600 mA before). Thankfully no errors!
However, as I had mentioned in the OP, I have a separate issue in which the RA axis gives up whilst tracking. This is still happening (no surprise there as I did not adjust the RA at all) so I will ask SB for further advice. What I've noticed is that the current consumption while tracking (400 mA) is higher than while slewing! The mount even runs hotter while tracking than while slewing (1 degree difference as measured by the Bisque TCS)
Though I'm still cautious about this good news, I hope at least one axis is fixed.
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