Jefa Direct Drive unit configuration/installation

UPDATE

We resolved the primary issue by realigning the motor arm and re-running the autopilot calibration.

We disconnected the drag link from the motor arm, then manually rotated the motor arm approximately 180 degrees from its prior position, roughly from 11:00 to 5:00. We then centered the helm and reattached the drag link to the motor arm.

After that, we re-ran the autopilot installation and calibration using the Zeus chart plotter installation menu. We used a 60-degree rudder swing, 30 degrees port and 30 degrees starboard, followed by hard-over to port and starboard, then centering the wheel as prompted.

After this correction, manually turning the helm hard over no longer produces the thunking noise, and the steering geometry now looks correct throughout the range of motion.

There is still some play in the motor spindle that we can feel by hand, and during manual rotation there was a point where the drive appeared to disengage momentarily. This may indicate internal wear or damage, possibly within the gear set, but for now the system is operating significantly better than before.

Thanks again to everyone who shared photos and guidance. It was extremely helpful.

One remaining question for those familiar with the Jefa DD1. The motor output spindle still has noticeable play that we can feel by hand, and during manual rotation there was a point where the drive appeared to momentarily disengage. Is any amount of spindle play considered normal on these units, or does this suggest internal wear, a loose coupling, or gear damage that should be serviced before continued use?