just for some info where i live it is gravle sand and mud road travle is usually alot of twists and turns the local 4x4 club president has gone thru 3 of these type of lockers and finally put in a detroit in his jeep I think the high rpm and loose / traction /loose types of terain may just be hard on parts I have checked the housing and it is currently out by 3/16 of an inch overall I was told by the vendor that the 1510 was pretty tolerent of this
i would tell you that you might have a bent houseing. i have had a locker eaten alive by a bent housing. and i didn't even notice that the housing was bent until i put my hand on the pumpkin right after a trail ride, and the dang thing was hotter than firecracker. but that is just what happen to me.