Just talking with Support they asked that I upload a video of the problem. Let’s not worry about my poor camera skills.
It doesn’t sound as bad in this video as when I actually run the machine.
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It makes a grinding crunchy sound when it goes down (not when Z goes up).
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look at the stepper in the video. You can see it physically trying to lift itself up when it goes down. I’ve checked all bolts and they’re tight, and I can’t move it by hand, so it’s really pushing hard to do that.
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not shown but Z isn’t consistent. If I Z to base plate, fast slew to 6mm and try to slide a Mitutoyo 6mm gage under it, it will fit with a little effort. (that’s good). But then if I jog it up and then fast slew back to 6mm, the gage is loose and slides easily under. Not sure if it’s related.
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Finally since this has started, sometimes when I jog to Z in .025mm increments, it’s as if one of the steps doesn’t happen. Jog down, it moves, jog down nothing, jog down it moves.