I removed the axle shafts on a rear axle with an e-locker that I'm planning on swapping into my 2000 4runner. I replaced the oil seals and cleaned everything up but when I went to reassemble everything one of the shafts will not fit back in. The other shaft slides in just fine. I even tried it on both sides no problem, but the trouble shaft stops at an 1" left on either side. I already checked the splines and they look fine. I cleaned them up with a wire brush a little but they were clean and not dented. Is there something I'm doing wrong? Thanks for any help.

 

Any ideas at all? I tried again today. There is nothing on the uncooperative axle that I can see would cause a stoppage. It came out smooth when I removed it as well. Thanks

 

From my searches it seems this is common. Seems you need to really work to get it in. I know that doesnt help you but its all i could find.

 

Update:

I pulled the third out again to troubleshoot. The axle isn't warped as I was afraid of. The malfunctioning axle shaft will not fit into the pulled differential. The good axle shaft fits smoothly into both sides. Looking at the spline, there doesn't seem to be any heavy damage. Some bumps on the end (probably from trying to get it back in) so I took a file and cleaned up the teeth some. Still no luck. Are there any techniques for repairing the axle shaft spline? Thanks for any help.

Jake

 

I pulled both of my shafts a few years ago to replace the oil seals. In my opinion, the splines are large enough that any damage should be obvious to the naked eye. I think you have a different issue.


Andreas