Guys, I really need help...
My driver's side CV Axle Shaft just won't go in no matter what I do. I've removed everything including the strut to get a clean clear straight shot to "float" it in.
It's an '91 A523 3:50 large spline with OBX LSD all redone by Cluff Ramsdell. Passenger side went it without any problems and is ready to go. Drivers side is giving me all kinds of problems. The differential has the oil grooves half way then the splines. I can "float" the shaft in to where you can see the splines any further and then it gets very tight.
I have tried 2 different brand new CV axles thinking that the first may have been milled wrong by just a fraction making it not go in. I can tap it in about 1/8" then it won't go any further. It might be hitting splines at this point. It's so tight you can no longer just feel for the splines and slide it in like normal. Once it is lightly tapped in by a 2x4 to 1/8" then it's just as hard getting back out. Acts almost like shaft is tapered it's not.
I have lubricated it very well using white lithium grease then tried Red Line synthetic back to white lithium. Nothing seems to help.
I have not tried the BFH...! If splines are not lined up exactly then I would have a very difficult time getting it back out.
HELP...