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I am adjusting my worm gears and I notice that the face of the gears that are connected to the servo motor are covered in grease,?and they must rub on the cover. Is this intentional?

I can see that the greasy gear is not in as far as the other one is on its shaft. I can also see that the 2 gears do not line up with each other because of this slight offset. I don't see this on Losmandy's videos.

Mine don’t rub against the covers but they are covered in grease around the periphery. The grease is somewhat normal as the gears push some of it away when meshing together. Rubbing against the cover can only add to wear and tear if you ask me but thankfully it’s an easy fix, just loosen the grub screws slightly and push the gear just enough to line it up with the other one, then retighten the grub screws.

As I was attempting to move the gears in, the allen wrench I was using was stripping out in the set screw. Also, there is some in and out play on the shaft which I guess is what is causing it to rub the cover. I am not really sure what size allen wrench is supposed to fit in these as all 4 of the set screws seem to fit the wrench differently. Some are tight and some are loose. I am going to order some new set screws from McMaster Carr, but I am trying to decide on stainless or black oxide alloy. I see the new 5-40 1/8" screws use a 1/16th wrench but none of the ones I have including the one that came with the G11 fit, they are too big. The next size down, .005 is too loose. I did manage to get the stripped one out by gluing in the wrench. That is how I conformed that it is a 5-40. I will need new grease as most is off now from the few times I have made adjustments to the worm. I don't remember what kind of grease they use for assembly, the gray stuff, but the stuff they have on the website is not gray and it is out of stock.

I had some black oxide set screws in my screw drawer this whole time. I am glad I had not ordered any yet. The factory screws were hard to get out as the allen hole was a bit too big, but they are all out and replaced. I used blue loctite. I moved the gears in a tiny bit that were rubbing the covers. If this was intentional, I can always move them out again. I left all the grease in place for this reason. I set the spring loading a bit tight and sure enough I had the RA Stall warning. I simply backed off the spring. Now on to some in house exercises.