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Is there end or side play in the bearing blocks on that worm?
I can't see any difference in the two worms at all. I didn't see any burrs, either. So, I just ordered a worm, two bearings, four thrust washers, and gear lube directly from Atlas. I might try the thrust washers first, to see if that solves the mystery, but I'll have the spare worm assembly, if necessary.DFF