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I found this thread because I was having the exact same problem. I know it's an old thread, but I think this info can help someone.
I have identified the problem, and it isn't a pawl adjustment issue. Do this: remove the shell plate, turn it over and look at the underside. Around the perimeter you will find a raised ridge. If you inspect this ridge closely you will probably find one or more shiny spots where the ridge is being polished as it rotates.
These shiny areas are high spots on the plate, and were caused by a manufacturing defect. The drag they cause results in the failure to index properly. (You may also notice slight resistance in the operation of the press handle.) Because they are not distributed evenly around the perimeter, they only cause the failure to index on certain stations.
If you call Hornady and describe the problem, they should replace the shell plate for you.
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