Help - New Leak

Put the seal flush. That has nothing to do with the cv not lining up in the diff

 

I left the axle seal flush. Spent maybe another 1.5 hours tonight trying to get the cv in. Is possible I damaged the splines and now it doesn't fit? I'm not sure what it looked like before so I have nothing to compare it to. I took the c-clip off and I still could not get it in.

 

I don't mean to sound rude or ungrateful through all this frustration. I really appreciate everyone's help. You all deserve some beers when we get done here.

 

Sorry to hear it still won't go. Try to stay positive bud.
Can you post a pic of the shaft splines?

 

My internet really sucks. Most of the pictures I tried to post didn't go. But give me a few minutes to try.

 

Copy that. I'm replacing u-joints right now but i'll keep an eye out for posts.

 

Well... just gonna be blunt here. Splines are screwed. And looking at the end of the shaft you more than likely damaged the inside where it mates to the diff.

 

Do I need to purchase a whole new cv? Is it repairable? Can I sand or file it down?

 

I shouldn't admit this, but I have filed down spines on the trail when I needed. You can get just the inner shaft separate though. Or if you don't really do any hardcore wheeling go with an OEM rebuilt

 

"Just to update: I banged on it for at least 2 hours with a regular hammer and crowbar. I said screw this and went and bought a 4lb sledge hammer and 2 hits / 2 minutes later it's in. Really helps to have the right tools. "https://www.tacomaworld.com/threads/cv-axle-install-question.160011/page-2

I just read this on another TW thread. I'm using a 24 oz hammer. Should I go bigger?

 

I wouldn't at this point. I can PM you phone if you'd like, be easier to explain

 

Yeah honestly man a lil chewed up. I really want it to work out for you though. It’ll eventually work, don’t let it get to you. Where you located?

Never mind, Bend, Oregon

 

Ok thanks. I guess I'll be sanding tonight.

 

This makes me feel like I got lucky when I replaced my CV axle on the trail...we just stuck it in and gave it a couple good whacks with a 4lb sledge hammer and it popped right in...was 8 months ago and no leaks or signs of anything broken. Maybe you do just need to use a bigger hammer...

 

In my head I can see how a bigger hammer might help get over the beat up lip. But I have also been wrong on every other step of this install. Lol.

 

Yeah lots of it. Try to match the pitch on the main splines if you are going to try. Good luck man. I've done it on drive shaft yokes and made it work but it's sort of a 50/50.
And like I mentioned looking at the end of the shaft before the splines, it is possible that the internal part mat be mushroomed

 

This might be redundant, but using a long punch against a flat spot on the “housing” was more effective than hitting the end of the shaft for me. The housing I’m referencing is hexagonal or octagonal. It has notches on each corner. That way, I was transferring energy more efficiently than trying to compress the whole shaft. And if it wasn’t lined up, I could kinda tell right away.

 

Good point. I will try to sand the possible mushroom part first. It seems much easier.

 

Just to clarify... I'm talking about on the inside of the axle tube where the CV shaft enters the internal shaft. That part may be buggered up too. Look inside with a light and verify they aren't deformed