i would put money on the locker sensor ring being on the wrong side of the actual sensor in the back of the diff. happened to me when i picked my axle up from a regear. it causes the locker ring to ride to the left causing the locker to partially engage.
might have to pull the carrier back out and verify the sensor is on the correct side when reinstalling the carrier.
to verify this is the issue use a dental mirror to try and sight the issue or partially unscrew the axle lock sensor and the axle should unlock. (reinstalling the sensor will require you to pull the carrier so dont pull it out if its not the problem)
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