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Swap out your hubs with new ones or just get some manual locking hubs, many of these things have plastic components inside and it doesn't take to many 60 mph engagements before the splines get shredded.
Are you sure the front driveshaft is being powered? Just because it is spinning doesn't mean it will take a load. A bent shift fork will make the driveshaft spin but jump out under load.
Aftermarket manual locking hubs solve many strength problems and are usually much cheaper than the factory replacement alternative, besides is it that much of a problem to switch the hubs over when your wheelin? I never cared for the automatic hub systems that have proliferated since the late eighties, they don't seem to take much abuse before they crap out.
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Outlawed tunes from outlawed pipes
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