1/16 of an inch causes total servo failure (theory))

[Assault]

There is a reason why The Great Pyramid's north-south axis is aligned to within three-sixtieths (3/16) of a degree of true north-south.

In this case 1/16 of an inch is the reason for common servo failure.


This is the epicenter of the catastrophe. As one can see, a portion of the wall was removed so the screw could be placed literally in the middle of where the gasket should be located


The screw hole needed to be moved 1/8 of an inch to the left (in the picture) and should be like the screw hole opposite of the one the pencil is pointed at (right side).


The wall that was removed from the servo is 1/16 of an inch wide and 1/16 of an inch tall. Even if they left the screw hole in place, I am unable to understand why (other than planned obselence) for the removal of 7/16 (length) x 1/16 (width) x 1/16 (height).

Once coolant entered the screw hole, it simply filled up the servo housing, since its under extreme pressure (think volcano). Conveniently there were 'drain' holes already built into the servo. (Which makes me beleive they knew this would happen (the aluminum ones have the drain holes removed). The only time coolant would drip out of the system is while the car was running, once the car turned off the pressure in the system stopped. However due to the constant flow of 80-100c coolant draining through an 1/8 inch hole it led to overstressing the plastic causing the infamous crack of death.

The servo is slightly tilted to the rear right (the side of the crack). And according to physics water follows the path of least resistance.



Once the water 'broke' the seal of the gasket, the gaset became useless, as it was soaking in coolant, as seen by the dried coolant pattern.


That is my theory on why these Servo's fail. If anyone has anything to add please do. And remember the proverb 'Measure twice, cut once.'