Hi rusty009, this seems like an issue with the bundle size, or otherwise some issue with the search head transmitting the bundle to the indexer. This is a tarball of config files, which tends to grow over time, and usually gets tipped over the edge by large lookup files.
My recommendation is to look at the internal log for the indexers and search on
index=_internal method=POST status!=200 source="*splunkd_access.log"
If you find events indicating issues, you can configure replicationBlacklist in server.conf to stop certain files or directories from being included in the bundle, or otherwise remove unneeded files entirely.
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