March 14, 2008 6:03 PM
Gear slippage is possible, I just don't think its likely. The only gear with a proven propensity to strip is the rack an pinion gear for the hands, and that usually manifests as the head / hands snapping closed as they head towards the outer most positions. Far more likely is a damaged sensors, or faulty wiring. Which could manifest as a joint that does not move quite right, and tends to try and move past its stops.
Grab your remote, and your manual, try moving each joint (I mean every joint you can) to as far as it will go in each direction with the remote (not manually, not using a puppet program), and then back to center. Watch for joints that don't seem to be moving right, or make loud clicking sounds.
You may also want to open up his chest and make sure that all the plugs are seated correctly and that when he moves, nothing is putting undue strain on the wiring.
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