Oy
Hello,
Let's back up a little: you have a cracked toggle. Nothing you have described can be utterly linked to that condition, and too many things that you haven't described could, so let's consider it separately first.
What kind of toggle is it? Options include double-jaw, strap, and forged. Do you have pictures? What is the toggle pin diameter? What is the diameter of the hole in that it attaches to? What is the wire diameter? What is the brand of furler? What is the tune on the backstay? On the aft intermediates? On the forestay (inner stay; let's call the masthead one the jibstay)? Where has the boat been in its life?
Get back on as many of those details as you can. Later we can move on to the rest of the system.
Fair leads,
Brion Toss
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