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I am not sure what I was thinking this morning, it is x-axis (the 120" long one) that is rack and pinion. y-axis and z-axis are ball screw and are working fine. (most of my work these days has been on MSY lathes and now a tube laser ... it seems every machine in my shop has different axis names ... and then I screw up the simplest axis named machined I own)

I am going to take tommylight's suggestion and give the rack and pinion a good cleaning. And look at if there is anything that could be lose / binding elsewhere in that axis.

Thanks

You have the old (G540) package name in your pinout file

While copying the file for pasting I noticed that while I had changed the package name at the start of the file, I had forgotten to change it at the end...

It compiles!! I'll flash it tomorrow 
Thank you for all your help!