Axle won't go in all the way
 

I had to replace my rear axle seals, and when I went to put the axle back in it won't go in all the way. I am doing one at a time, and the one that I'm having an issue with is the passenger side. The driver's side axle is still installed.

I have a 12 bolt posi Mosser rearend with the retaining brackets on the ends of the housing (no c clip inside the differential). I don't remember having an issue with this the last time I had them out.

I tried to have someone rotate the other tire and see if that would help it seat, but I just can't get it.

It's only got about 1/4" left to go, but the retaining bracket was flush when I took it off and now it's got about 1/4" of gap in there.

Anybody have any ideas? I have not had the differential cover off yet and was hoping not to have to remove it, but if it's a must I can - I just didn't have to the last time and am confused about what's different now.

Are the axles the same length?

Are the seals the same and installed at the same location on each axle?

Are you moving it up and down to "find" the hole on the inside?

The first time I re-installed the axles on my 12 bolt, I had the same problem. I found that you have to "thread the needle" on the far side of the axle tube, and that it takes some wiggling.

Steve, not sure if they are the same length or not. I am only doing 1 at a time and haven't removed the drivers side yet. It just came out of this side so I know it fits.

Chris, I did move it up and down to find the hole, and the splines are engaged enough to be able to turn the differential and drivers side tire. I tried to wiggle it more but it's engaged enough to where it can't move up and down anymore. It feels so solid that I thought it was all the way in, but since there is a 1/4" gap in the retainer clip I know it's not fully seated.

I read online that if someone turns the drivers side tire forward, and I fight it on the passenger's side and turn it backwards it should seat, but no luck.

So it sounds like your doing this with the cover on, that may need to change.

First you give it a talking to and then some gentle persuasion.

Yes, I'm doing this with the cover on. I figured since there were no clips inside that I wouldn't need to remove it.

I was hoping there was something I was missing, but maybe I will just have to take that off. I was trying to avoid that...possibly out of laziness haha

Ace, I did try a little gentle tapping with a dead blow hammer. I wasn't sure if that was the right way or not, but it didn't seem to budge so I took to the internet.

you guys smoking pot or meth??????
should go in no problem

Since you changed the seal, it's probably not seated all the way?
Or the wrong size? (axle not going all the way through it)

Is the Moser setup like the Ford or like the C-clip eliminator they used to sell for the 12 bolt?

Or even the splines could be twisted a small amount?

:confused:

Seal is the correct size - I actually called Moser for the part number since it's an aftermarket setup. The seal sure feels like it's seated all the way, it made that different noise and you can feel when it's in so I think that is in. I guess I could measure that space and the outer bearing with the micrometer though.

I'm not sure about the c-clip eliminator, but I might just have to give their tech line a call.

The splines shouldn't be twisted at all...I've only driven it on the highway twice now.

I have the same Moser rearend. The seals sit inside the axle tubes, then the bearing sits inside the Ford end housing. So the seal can't be holding the axle from going in or the axle tube would push the seal in more. What type of bearing is on the axle? Some come with a rubber o ring on them. I would remove your seal and see if the axle goes in. Only thing that comes to mind is twisted splines. but seeing you only drove it a couple of times that can't be an issue. There is also no C-clips on mine and shouldn't be on yours. The C bracket holds the axle bearing in with 4 bolts. I wouldn't be using any hammers to get axle in, Take your time. Remove the back cover to see whats going on. Pull your axle back out and check for any burs on the splines. If it still won't go in take the driver side axle out and try on the passenger side. It should side in with minimal force. As was mentioned, check the seals fit the axles before installing the seals. Put a little grease on the seal and axle and side the seal all the way toward the bearing end to make sure it fits.

Was the axle hard to get out? Wondering if housing is bent slightly. Yes take your time. Cover all the bases.

I'd take the other axle out...since you're going to anyway...and do a side by side inspection. If there's absolutely no difference in the two that you can see, try it in the other side. If no solution, pop the cover.

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Drop the cover.........don't keep guessing at what is wrong. Find out.
 

Messy - yes.
Smelly - yes.
More work - yes.

Worth it so you can SEE what's blocking the axle - PRICELESS!

Good luck!

Got it figured today. After reading all of your suggestions, I went ahead and took the drivers side apart, and quickly realized there are two lips on the inside of the housing, and the passenger side seal was getting hung up on the first lip so it felt like it was bottomed out, but it wasn't.

A couple of you mentioned that early on so thank you for that. I tapped it in all the way and the axle went in perfectly. The drivers side was a breeze - just like it's supposed to be.

The passenger side seal is very slightly deformed due to pushing the axle in when it wasn't seated. I think it will be ok, but worst case scenario it leaks a little and I replace it again.

I'll post a pic of the axle housing to show you what I was talking about.

Yup!
These are the times when a little wheel bearing grease on the OD of the seal would have been the cure.

Well, lesson learned that’s all that counts in the end!

Absolutely Steve...Old cars come with lots of lessons learned!

Awesome. Glad you got it figured out. And thanks for
The feed back.

Yes glad you got it. I've 'fallen down' alot,dust yourself off. Then you'll remember not to do it again,learning experience.