Cv axle won't go in all the way

I recently swapped my front diff on my 96 Tacoma. Mine was an ADD and the used differential I bought came off a 98 with manual locking hubs. I swapped everything over got it back in, no issues. Passenger side cv slid right in with ease. Gave it tape and it went in completely.
Now the driver side, I put it in, gave it a tap also but there's still a gap. Lifted her, threw it in 4wd and let the wheels spin and all 4 spun like normal. So it's obviously sittin in there fine, just not going in all the way and I'm slowing loosing gear oil from that gap.
Anytime I try to hit it in, it almost feels as if it's just hitting a wall.
I've pulled it out plenty of times, turned it and tried again but no luck. Everything looks fine from the c-clip to the splines.
Anyone know what's going on?

 

Take the axle out and put some grease on the c-clip to help keep it in place. Now, with the opening of the c-clip pointing down, get it started on the splines. Grab a long pry bar or similar tool and rest the end on the flange of the inner joint. Strike the end of the tool with a hammer and knock it in. In the video below, watch between play time 53:40 to 55:00. This is the technique that worked for me to get the driver's side in but not the passenger side. In the video time between 53:40 to 55:00, I'm working on the passenger side. I was able to push the axle in just with arm strength on the passenger side.

Also, start watching again at 1:17:30 to see how I check to make sure the axle is fulling seated.

By the way, this is on a 2002 4runner but I imagine they are very similar.

If the thought of pulling the axle out again isn't all that appealing, I'd try to pop it in from one position giving it a few whacks with a hammer and pry bar. If it doesn't go, rotate it a quarter of a turn and try a few more whacks. Hopefully you'll find the sweet spot and the mofo will finally pop in. Good Luck!

<iframe width="560" height="315" src="https://www.youtube.com/embed/vcCT4UgFUTw" frameborder="0" allowfullscreen></iframe>

 

Weird. I've read many posts of people saying the c-clip opening should be facing up. Not down..
Maybe that's my biggest issue. Sure hope so

 

The FSM definitely suggests having the opening of the c-clip facing down.

 

Dab the clip with grease and try to keep it from sticking out one side or the other and then put it in. Smack the end of the axle with a rubber mallet.

 

These axles were in or out when you bought the complete set up??

I have heard of different length axles .

ADD CV axles and locking hub axles are quite different if your trying to use your ADD axles

 

I just bought the clamshell.
So I'm re-using my old cvs from my ADD.
But if that were the case, why would the passenger side sit normal?

 

just double check the one you're trying to fit is exactly the same size. I bought one once that wouldn't go all the way in because it was about 1/4" too LONG! There I was bashing on it for a few days.

 

Compare the tube length on the passenger side of the clamshell to verify that tube is the same length between your original and the new clamshell.

 

So I took off the c-clip from the axle to see if the c clip was the problem but even without the c-clip it hits and isn't sitting all the way in.
So I'm assuming the Cv axle is slightly too long.
Anyone know where I can get something a little shorter?
Need help ASAP! Gotta get my truck back before the weekend is over

 

No actual experience here, but ....

It sounds like your problem may be due to trying to use an ADD CV axle with the non-ADD clam shell.
According to the RockAuto web-site the ADD axles are about 3/32" longer (compressed length) than the non-ADD axles.
I don't know where the difference in length comes from, but it could be in the stub that goes into the diff.

 

This is true.

But this is odd as manual cvs are shorter. So if anything he should be having issues binding. Not a gap.

OP: did you swap the ADD tube over as well? I would hope you did.

Are the cv axles OEM?

 

Yes sir I did. I had to swap the tube over in order to get the vaccum lines back.
So anyone have a way to find the right cvs?

 

Oh yea, I also forgot to mention it has a lock right locker in it. Not sure if that could possibly have anything to do with it.

 

Contact the locker Mfg. Tell them your story. They might have a oh yeah moment to share.

Check your loss with a ruler if you can first. Compare axles at Napa or a junkyard. Get what you need.

 

Thanks! All look into all of it as soon as I can

 

What was the solution to this problem?

 

I too am interested... mine is currently stuck on the last 1/4"

 

I’m stuck on this too, my drivers side has a 1/4” gap and is just about shot

 

So I was stuck on this and apparently a small gap is normal. I made a thread yesterday on this.

https://www.tacomaworld.com/threads/help-cv-axle-wont-go-in.681820/page-3