I checked Randy's axle listing, it states the axles I have should not be used with factory posi with 2 pieces side gear, could this be the problem? The Power-lok (clutch style I believe is the 2 pc side gear).
I saw the exact problem when a guy in our club used Yukon axles with a power lock. I didn't do any measurements on his but I did clean out the sure grip and checked things out for him and it looked like the axle just didn't engage into the inner set of splines like it should have. He bought a longer set of axles (28" long I believe but I'm not positive) and put them in and hasn't had a issue since. Another thing to make sure of is that the factory thrust pins are removed from the sure grip. If not they'll keep the axles from going all the way in. Another route you could take is to buy a 1 piece side gear kit from Dr. Diff. That'd be cheaper than buying new/longer axles and should work just fine since there's not much of your axle damaged.
