well, long story short, i had a split in my driver's side CV boot.

with funds being a bit tight, i'm doing the job myself. No big deal, i've done suspension before and also helped when my mate did the manual conversion for me.

I've taken the joint out, boots replaced and ready to go back in. For some strange reason the shaft wont QUITE go get back into the back of the hub.... Doesn't seem to matter how much i bend and twist the lower arm/ball joint etc it's still barely millimeters out!

anyone else had a similar problem? the join to the half shaft etc all seem good, i just can't figure out whats changed!

from memory its a bit of an A#@ of a job and u just have to play around until it goes in. as they say its the angle of the dangle

I am very un-knowledgable about this - but I know there is like a spring clip on the end of the shaft, and that it can be fiddly to get in/out.

Is it possible you haven't pushed it all the way in? Hence not having the last bit of play?

He's talking about the wheel end of the shaft. There's no spring clip.

If the shaft is in the gearbox properly and the support bearing is bolted to the engine you should be able to maneuver the shaft back into the hub just by playing with the angle. Unclip the brake fluid and ABS lines, that'll give you a bit more room.

If you really can't get it in, you can pop the lower control arm ball joint and let the whole hub hinge on the steering knuckle. This will give you more than enough room. Ball joints are a prick to get back in though.

Check you have not damaged the spline when you removed it all as well, have seen this happen before

IF it is a distance thing, avoid the lower joint however drop the tie rod, they are a tighht fit. Also make sure your shaft is all the way on the intermediate shaft

Mal

i've played with the intermediate shaft a little, and it does seem to be on there nice and tight. (if i try and pull the drive shaft out again, it just moves the inner joint, while remaining attached to the intermediate)... so i'm pretty sure its on there tight... weird! will have another look tomorrow

from memory its a bit of an A#@ of a job and u just have to play around until it goes in. as they say its the angle of the dangle

I am in agreement. I currently have 2 new drive shafts and 2 knackered ones sitting on the shed floor until 2 morrow. I have however had the new ones in and had to remove them, so after saying that, I D/C the strut tower and found its just a matter of plain with it.

I also undid the brake line and the abs lines to give better movement. If that isn't the case its out of my knowledge level.

He's talking about the wheel end of the shaft. There's no spring clip.

What I meant is if the thing wasn't pushed all the way into the gearbox, you may not have the play you need to get it into the hub.