Humour me here, I’m struggling to get my push-in shaft to go back in on my MK1 1.8i 1995. Here’s some background:
Both shafts have been out and back in when I originally rebuilt the back end in 2022.
Back left wheel bearing has gone twice in quick succession so I’ve changed the outer CV joint and upright to try and find the core issue. I took the whole shaft out to do this as it’s easier to take it in to my garage to work on.
Now 6 weeks down the line the shaft doesn’t want to go back in, even with persuasion. I took the clip off to see if that’s the issue, even with the clip off it stops 1 inch short, there’s no engagement with the splines.
When taping it’s almost like a solid metal stop I’m pushing against. Almost a bounce back when using a copper hammer
Is there an alignment or something, I checked the splines and they are ok, checked the diff and no burrs or broke clips remaining. Do I need to align the yoke inside the diff or something?
I’m out of ideas, last time they popped in with a gentle tap using a copper mallet.
Just thought I’d close the loop..
Despite the shaft coming out and the CV joint being swapped at the outer(wheel) end. The diff splines somehow got marginally mushroomed, only with a vernier to measure and compare the end vs middle diameter would it be noticed. Marginal, but it was enough to stump me!
Car back together and on all 4 wheels.
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