I engaged my 4wd (using my posi-lok)the other day and when I took a right turn, I heard a loud bang (maybe clunk). After that, I could move the posilok handle but no engagement. I pulled of the housing to day and the fork moves, but the axle splines look (to me) to be in bad shape. It also seemed like the outside axle had a bit more then a 1/4" play.

I guess I'm not sure where to look at what went wrong. I don't want to just adjust the cable and make things worse. Any suggestions?



Edit: Added Pic

 

sounds like the fork is not engaging the collar all the way, jack up the front and move it by hand to see if both axles lock.

 

I agree, but it worked fine for at least a winter, so I'm hesitant to just adjust it. I'm sure if I try to manually move the collar, it will work.