My previous trailer, a Keystone Outback, had this exact thing happen with my kitchen slide. I ordered the gearbox from the dealer and replaced in about 30 minutes, then spent three hours performing adjustments...a real pain. I learned from that incident that cable slides are somewhat high maintenance. There is a BAL guide to proper adjustment. I even carried a set of cable ends and the crimping tool to ensure I could fix on the road.
I used channel locks to force passed the gear during operation...wife operated, I forced it...had to remove the facia to get to the gear.
Going by their guide, cable tension should be checked every 90 days. There should be no slack in any of the cables, in or out...as slack may eventually lead to cables jumping pullies. You can see slack in cables from stretching over time...especially where we are now, lots of contractors that full time here, haven't moved therir trailers in 12-18 months and there is noticeable slack in cables as you walk around and look at the trailers.
Cale
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TV: 2015 F-350 DRW, CC, 4x4, with 14k GVWR package, 98 gallon TransferFlow Aux Tank, Timbren Shocks
TH: 2014 Voltage 3950, Sailun S637 all around
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