Bob,

The programmer should be updated to reliably interface with the revision v1.04 5955TG servos. The deviation from programmed parameters is an anomaly realized with v1.03 firmware > v1.04 amplifiers.

Why is setting the servo arm parallel to the hinge line of interest? More likely than not you’ll need to have several degrees offset at the servo arm to the rear to find the surfaces travel arc center.

The Linkage Design software you have should estimate very closely the exact offset required or the paper protractor method works real well too.