All this talk of deadband - correct me if I'm wrong, but "deadband" refers to the servo's centre position only and how much "margin" there is either side of (say) 1520us before the servo tries to move. So if this was a deadband issue, the jitter should only show up at the centre position. If, on the other hand, it's related to mechanical backlash in the drive system (i.e. the servo's backlash plus the belt drive's backlash) then the jitter will occur at any angle. The revelation that varying/removing any restraining friction on an axis alters or removes the jitter issue further confirms that it's likely to be backlash at the root of it. This suggests that PH tuned the algorithm to cope with an "ideal" setup and didn't test across a sufficiently wide range of variables to ensure that the system would cope.
Has anyone tried this "on the bench", i.e. just hooking up loose servos without anything attached to them?