Today I replaced the driver's side half axle. The old one came out easily enough. The new one, which is a remanufactured unit, wouldn't click in. I'd engage the splines, but couldn't get the circ clip to click in. The old one would go back in easily. The I tried the new one again and got nowhere. I banged away with a rubber hammer on the end of the axle with the axle compressed, but got nowhere. I called a parts store and they said to just bang harder. Finally, out of desperation, I used my two pound hammer, and that eventually got the inner joint to sit flush with the transmission case. (I ended up rounded the outside end where the big nut goes, and had to file that down to get the nut on.)

Now, somewhat calmer, I'm concerned that I may have damaged something. It runs fine, but can I be confident that the circ-clip has properly engaged? Might I have damaged the axle with all the hammering? Why did I have to hammer so much? I'm confident I had the splines engaged properly.

I compared the old and new carefully. The only difference I noted was that the inner metal cannister was a bit shorter on the new one than the old one, but the inner shafts with the splines and circ-clips were identical.

I certainly don't want to try pulling the shaft out at this point to check on anything. I suspect it would take enormous pressure to pry it back out.

Thoughts?

Now I'm worried.