I've popped it apart 50 times or so already, so one more won't make a difference. I'll see if it's all the same or whether the diameter is different on some of them.

I have 85 balls in the nut, the max capacity is 92-97, so I've lost 7 or more somewhere, although according to Gary (Zapp) they never load the nuts full to the brim. I've definitely lost a few somewhere as I've dropped the retention tubing at one point and the balls came flying out.

I've realised the return plate can go on in two different ways, so I've rotated it 180deg and it made things better, only to get stuck under load. I've assembled the Z-axis, popped the ballnut on the ballnut support and tried moving it, it crunches ever few turns and something definitely gets blocked. If I lay the Z-axis horizontal, nothing gets stuck as the ballnut is not loaded. I took a hit and ordered another ballnut, so hopefully that will end this nightmare.

Regards,
dsc.