Hey Craig,
Do you know about how long ago your signal was purchased from Russ? I know there was a batch of VW signals that he was concerned about and stopped using in the past. They were from a different manufacturer at the time.
I believe your issue has to do with those same internal tabs that can cause the clicking. I don't want to make it sound like greasing those tabs is a solution for everything, like a Windows computer fix(did you try rebooting it???), but I know it helps. It's why we're disassembling and greasing every unit that goes out now.

-TJ
www.mountain-metalworks.com