The rear driver side axle refuses to lock on my newly installed spartan locker. The initial test drive resulted in the usual ratcheting, along with an occasional loud clunk when making u turn, normal or so I thought.
On its maiden voyage, 90 miles into my trip to the rubicon, I noticed the clunk was becoming more prominent, I had not yet taken it off road. On the mild dirt/rock road to the campground, the clunk became constant, straight or turning it was always there.
Inspection would show the driver side coupler unable to lock up and stay locked up, pulled the diff cover, slight pressure on the passenger side tire pulls the driver side coupler apart, doing the same on the drivers side on make the driver side spin.
I have taken it out and verified my install, I even tried adding a shim to the driver side coupler, this only resulted in not bring able to get the cross shaft back in. I'm at a loss here, my gap measures out just over the minimum spec of .145, none of the springs are bent.
I do have reason to believe that my driver side axle tube is slightly tweaked, the carrier is what holds the locker parts, and the axle splines appear to be squared up in the carrier opening.
Any suggestions are appreciated.