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+1 to CDN_Stalker's diagnosis.
Because of the Sorbo pad's thickness, it can cause the piston's "at rest" position to be to far back, causing a misaligned of teeth between the piston and sector gear. A fix for this is simply to remove the second tooth on the piston (and possibly shave the third tooth down to half).
Also, I've had spring guides on which the ball bearing's outer diameter was the same or greater than the inner diameter of the piston, and the spring guide would stop rear-word motion of the piston, causing a seize. Simply take an exacto knife and drag it around in circles on the inside of the piston at the rear, to make it "fluted" a bit.
(And spring length shouldn't be a problem unless it's too powerful a spring fand requires more torque than your gear/motor combination can provide)
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