Rear axel shaft installation 1st Gen 4x4 - need assistance

Wyatt987

New Member
Jul 30, 2020
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I cannot reinstall the passenger side rear axel shaft the " last inch " required for the backing plate to nest against the axel housing. I am at the location where the bottom longer protruding studs start to enter the 2 bottom holes, however top studs are still a few millimeters away from entering the top holes. I have a 2002 SR5 4x4. Drivers side will slide in the last inch with a wiggle. I had my brother wiggle the drivers side while I attempted the slide-in. I attempted both with Trans in park and in neutral, so drive shaft is not locked and I have also gently turned the drive shaft a few degrees either way, and still no entry. Shining a light down the tube on both sides look good, everything lined up in the center and concentric. Suggestions? Thanks all!
 

Wyatt987

New Member
Jul 30, 2020
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After further examination and comparing to the other shaft that slides right in, I believe the cause is the the spline end of the shaft is smooshed, perhaps when the machine shop pressed off the old carrier bearing. I filed down between the splines however this did not help so I will use a grinder wheel in the grooves to clean up the smoosh.