that could be i'll try it hopefully thats it cause it has had me stumped for a long time  

gordee:
t case is fine you can watch it spin

Spin under a no torque load?  

i took out rear drive shaft and the front just spun  would not lock in  

had a grinding sound but i found no wear on anything all gears look good shafts look good no shavings or chips   do you happen to know the torque specs for a power locker i took it apart to inspect but want to make sure its torqued right  

What are you calling a "power locker"? Is it a spider gear replacement locker?  

the diff is a dana 44 power lock  

This is a complete Dana 44 power-loc limited slip carrier with all internals, requires carrier bearings and install kit.
The Powr-Lok is similar to the Trac-Lok onlybecause it is a clutch type differential.
The similarities end there.
With its 4 pinion spider gear set and two-piece case, some will argue the Powr-Lok is the strongest clutch type differential available.
The power-loc will give you a 90 to 95% lockup  

I know what Power Lock LSD is and how it works. I just was not sure if that is what you were referring to. There is nothing in that differ that could cause this short of bad spiders or bad splines in axle/spider side gear area. If clutches were worn out, it would still have normal diff functions. You are overlooking something here. It is pretty simple. You engage Tcase and lock hubs and either hubs are not properly engaging fully, there is a spider/spline issue in diff or Tcase issue here. (or a remote chance of a stripped pinion flange on pinion)  

how would i check to see if the pinion flange is stripped  

gordee:
how would i check to see if the pinion flange is stripped

If drive shaft rotates and axle shafts do not, it is either pinion splines or spiders/splines  

how do i remove the pinion i have the axle tore down but could not figure ou how to get the pinion out  

You have to remove carrier then you remove pinion nut and remove drive flange and pinion will then easily push out through case were diff carrier was. Breaking pinion nut loose can be a bear because you have to hold flange well breaking nut loose and it can take several hundred ft lbs to do it. An easy way is to use a 3/4 inch air wrench and it will zip the nut right off. (1/2 inch one will not likely do it)  

i have carrier out the pinion nut is off i took off the yoke the teeth on both look ok the pinion is all one piece right if so it has to be the lockouts like kiethpappa said thew hub bearings might need adjusted  

Do you have the spring behind the cluster gear that rides on the stub shaft in place?  

behind the lock out ya i bought new springs  and the retainer plate