I'm almost embarrassed to say, I still have not recognized the problem. Other than your lathe needs some work. If you're working on something that's real light, and you're constantly having trouble with it that adds to your setup times, then pleas just sell it and get a nice used lathe somewhere that was a good one when new. If it's just the chuck, you can replace it you know? If it's just the jaws, you can take a ceramic or CBN insert and bore them. There is this misconception that hard jaws can't be bored, well, that's not true. Now, I'll admit, a new chuck will be a damn site cheaper than a box of CBN inserts, but if you can get one somewhere, even a broken one, it'll work great for what you want. And ceramics are cheap (comparatively).
As best I can tell from reading this thread, the trouble isn't in the parts, it's in your machine. And there's no reason you shouldn't fix it. The time spent on that will be made up on the next two parts you put in it. Maybe just pull the chuck, pull anything behind it that looks like it is easily removable, and clean those parts. Maybe there's a chip or some dirt in the chuck taper or on the face where it mounts. Look for stuff that's been smashed in so hard its now connected. Feel around. Make sure it's clean.
I could almost bet there's folks who know me reading this thread, laughing, thinking about what would happen if Ole Phil had a tool that didn't work as intended. Lifespan in current fom = short...