Potentiometer with simple structure, stable performance, adapting bad environment characteristics, widely was used in servo system. However, the unusual and interrupt of potentiometer output signal caused the servo system performance degradation or not work, even seriously impacted on the use of servo system. According to the application situation of feedback potentiometer in the servo system over the years, the reason of potentiometer output abnormal mainly were brush fracture, loosen rivets, gasket rupture, wire fracture, join between brush and the center silver belt , having excess or defects on the surface of resistance film and conductive strip etc. The cause of the failure was determined by the failure mode analysis. The suggestions and methods of eliminating faults were presented, and were applied in the production process of feedback potentiometer. Thus the reliability and safety of the servo system have been improved.