The problem seems to have been resolved by turning the gears on the Black IU. The previous tech said he tried a couple of Black IU and they did the same thing. The code would appear within 15 copies. After turning the gears it ran 500 straight. So it appears that it was a case of the IU being stored wrong.
Thanks for all the Ideas, I'll keep in mind the spring clucth info also.
One machine fixed and 500 to go.
