I would GUESS it"s working loose, even with Loctite, because the gear and/or splines are worn and there"s movement between the shaft and gear, even when the retaining bolt is tight.
That being said, did you use a Grade 8 bolt, and high-strength Loctite, with primer?
NOT quite sure how it all fits together, but could the locking wedge/gear/shaft combination be worn in such a way that parts bottom out against each other before the wedge is pulled into place and collapses tightly?
A quick look at the parts breakdowns shows some serial number breaks on the parts, as well.
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