Alright, so some of you may know that I was considering making my own posi-lok a while ago because of 4wd problems. Well, I've been wanting to really narrow it down before I spent any money on doing this, and I figured out a way to keep the fork engaged just enough to test and see if the popping went away...well, it didn't. I had checked vacuum lines like crazy among other things and couldn't figure out why it wasn't engaging well.

Anyway, today I took the CAD unit back off to get the shift fork back to normal and I noticed large chunks taken out behind both the pads. I can't remember if they were there before, but from the looks of them, it's been that way for a while.

So what could cause something like that? What should I look at next to try and fix this 4wd not engaging thing?

 

The same folks that make Posi-lock sell HD shift forks. My guess is they do it because the stock units break.

 

I guess I just don't understand how it could be damaged where it is since the area appears to sit inside the collar.

 

Can you post a picture or two showing the damage?