:mad3:Ok, wow am I frustrated. I am having a really wierd issue. So I broke the long side axle shaft so I tore the axle down to replace it and check everything out while I was at it. I checked the short side axle and the splines on the inside were all twisted so I replaced the axle. SO the long driverside goes together fine, now I'm trying to put the passenger side together and the spindle WILL not go flat against the knuckle. THe top will touch but the bottom wont lay flat, its like 1/2 inch out. SO i tried a new axle, same thing, I've rotated the axle, hit it as far in as it would go, pulled it out a little bit in 1/8inch increments, still same thing. I am totally stumped. There is nothing in the way, I even tried the spindle from the other side and it still wont lay flat. WIth the axle out the spindle will lay flat fine. I'm really just out of ideas. Any help please, I'm supposed to be going wheeling in big bear today. Thanks.

Obviously the axle's not going in the diff all the way. What year is the diff housing? Are you trying to put a samurai shaft in a narrow sj413 housing?

Compare the length of the replacement shaft to the one you took out. If they're the same dimensions then there might be something stuck in the side gear that's not allowing the axle to slide in all the way. If the diff is welded you might have some slag on one of the side gear's splines. That could prevent it from going in all the way. :D

Bent housing.