Same thing here and in talking to my Distributor they have 2 others that came in the same shipment (so 3 SO FAR out of that batch) that have the same JetPack issue.

Here's the description I sent to my Distributor and CC'd $TERN Support:
"In JetPack Motor Test I can hear the Gearhead Motor try to go in 1 direction continuously until it times out (I don't hear it stop-start or have a slightly different sound running like when running the JetPack Gearhead Motor Calibration Test), the JP Arm won't not move at all unless I manually move the JP Arm forward from the Home position and then it goes completely left, it HITS! the Missile and returns to "Home Position".

In JetPack Motor Calibration Test I can hear the Gear Motor change directions (I can hear the Gearhead Motor stop-start & have a slightly different sound running - so I'm assuming it's running in the opposite direction) and then it gives me the same Error message that Kristen showed above if I move the JP Arm by hand while in this mode it will move.
JP Motor Cal Error (resized).jpg

Just got an email from Game Exchange (JJ and Jim) with a pic and Manual Part breakout that they got from Stern support.

Jim asked me to check Stern's pic against my Mech to make sure it was assembled correctly (IT WASN'T).

I disassembled my "5.56 JET PACK CLUTCH ASSEMBLY 511-9768-00" [page 62 in the Manual] and the five BELLEVILLE DISC SPRING 's were stacked wrong ?!?

P/N 269-5007-00 Spring/Belleville Washers #1, #2 & #3 were incorrectly ALL facing UP towards the Timing Belt Pulley Flange.
P/N 269-5007-00 Spring/Belleville Washers #4 & #5 were facing each other correctly.

The cupped Washers should be stacked - #1 facing up, stacked on #2 & #3 facing each other, stacked on #4 & #5 facing each other.

I added the numbering to Stern's "capture" Pic for clarification of the Disc Springs orientation.

With the PF resting up on the Lock-Down Bar the JP Mech works correctly (but still getting an ERROR), as soon as I put the PF back down into the Cabinet the JP Mech won't work in Test (or playing) it seems that the Cabinet mounted Post (see pic) was stopping the JP Mech from going all the way back it its "Home" position.

It looks like if it can't find the "Home" position the Code disables the JP Mech AND then stupidly leaves the JP in the way of the Ball , making you have to pull the PF Glass and move the JP Mech out-of-the-way by hand.

I took out the Cabinet mounted Post and after trimming the Clear Ramp Plastic (causing the same thing, not letting the JP get to the "Home" position).

I'm still getting an Error message but the Game seems to be playing normally.

Please post in this thread if you are also having this issue (or HAD this issue AND fixed it ;-}).

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JetPack Clutch Assm 1 (resized).jpg

Capture - Copy (resized).JPG

Cabinet Mounted Post (resized).jpg

Post Removed Ramp Plastic Trimmed (resized).jpg