Originally Posted by millball
Hard to tell without looking at your hub assemblies in person, but I think it's possible to incorrectly assemble the hubs to where the spring and retainer won't permit the splined dog to come all the way free.
Also, are you sure that you have the correct hubs for your application??
i never disassembled the splined outer hub gear from the retracting fork as they seemed to be the same side to side so i assumed they were right.
as for the right hub i only know of 3 toyota Asin manual hubs:
strait axle- 30 spline inner gear
IFS 86-95- 27 spline inner gear
tacoma 96+- whole body is different.
are their other variations i am not aware of? from what i understand from SA hubs and IFS hubs the only difference is the inner hub gear spline count right?