Transfer case actuator gear failed again

[pghguy517]

About 2 months ago I got the 3 lights (ABS, DSC, and 4X4) and clicking noise when shut down. It was a stripped plastic actuator gear like many others posted here. I replaced the gear with an Odometer Gears brand, and its been working great until last night. Same 3 lights and clicking sound. I'm sure its the gear again. What would cause this to happen? First gear went out at 96,000 miles, now at 100,000. All looked good inside the actuator (except for the stripped plastic gear), no sharp teeth on the metal worm gear, no excess slop in the gear and shaft. cleaned out the old grease and broken plastic gear parts, used the recommended marine wheel bearing grease. What gives? Thanks for any help on this.