Some time ago my vacuum actuator on the front axle went south and I installed a Posi Lock set up. Recently while towing my camp trailer around out in the boonies, and running in 4wd low range, I came across a situation where I really had to get on the gas to get up a dirt hill with the trailer. Something in the front end did some really loud banging (maybe on one second intervals), and the back tires were the only ones breaking traction. I stopped and backed up turning the steering wheel & pulling on the lever to insure the posi-track was really engaged. In fact I had to do that a couple times. Finally the front wheels did engage and the rig went right up the hill. But even at that, it banged once or twice more going up the hill.

When I got home, I took off the posi lock and checked to see if full lever movement moved the shift fork it's full travel. It does. I checked the axle coupling to see if it will slide back and forth like it should. It does. I put the posilock on and back off both in 2wd and 4wd, and the fork and coupling were in the right position each way. So I bolted it back together. There was a little wear on the axles where the coupling engages.

Last weekend at the Motocross track's campground, I ran into the same situation with the same results. The place I had parked the trailer was at a rather steep slope on a grass covered hill. To get out I had to shift the posi lock several times to get it to engage. (Again, I am pretty sure the coupling was not engaged even thought the lever was all the way out) The banging that occurs is full of energy and quite scary! Something is gonna break bad if it continues to happen. (getting stuck will be the least of the bad things I envision) Under light load conditions it seems to work fine.

I am relatively sure the banging is from the front axle coupling, but I could be wrong. Is it possible to make the coupling over travel? Any insights on what I should do next?