on 505 I have the same problem ... and I tried to feed it either way ... so am running with one jib halyard and one useless piece of wire and rope. I cut off the shackle and even running the wire end through doesn't work.
I'm thinking that the wire has worn the groove so deep that the splice just can't get over it.
My plan is to try to get a rebuilt halyard box by OCT 1 so that I can replace it during the one week I have scheduled for mast out work. If anyone can provide me a rebuilt halyard box I am paying T&M as we used to say ... and I will return the old one.
