Tony,
You are right you should never man-handle a servo
by manipulating the surface. I gently move the surface to look for gear problems. If 
you apply a quick rotation or quickly change direction you may damage the nylon gear 
used as a fuse in a metal gear servo. Never push a Flap to full deflection=over 
center, and then manually try to return the flap.What I do is feel the sevos mesh 
looking for smooth operation. If you suspect a damaged gear move the surface away from 
center and turn your radio on. Move the surface you suspect by radio command. A damged 
servo will usally grind and or respond with a jerky motion and gradually lose its 
ability to hold center. Best wishes Larry
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