Outer Limits 4x4 Board

I have just finished rebuilding my swivel hubs and bearings in the front end of my GU. The drivers side went back together sweet.

When going for the circlip that holds the free-wheeling gear on the end of the stub axle, Im coming up 2mm short (the width of the circlip basically). I cant get anymore length out of the axle/CV. I have had the hub off twice, checking seals, cones, cups. All appears to be ok.

Now Im no expert at it (first time doing swivel hubs) but with my Gregorys and the successful completion of the drivers side first, I cant figure out whether I have installed something incorrectly.

Any wisdom greatly appreciated.

cheers

PAUL

EDIT: The only other time I have had this issue was when the back bearing stayed on the shaft, thus not seating properly. Its definitely not that.

is the spacer that the free wheeling gear sits in all the way in? had the same issue on mine this morning, just needed a little tap.

Yeah. Even checked (re tapped) the spacer that sits behind that.

you will find 99% of the time this happens the seal on the back of the spindle is not taped down properly.
have seen this plenty of times slip it off and make sure its on properly.
then if it still wont come out far enough its just a matter of working it until the circlip will go on as the seal is new it will need to compress slightly.

But I even over tightened (a lot) the bearing and it still wouldnt go together.

Had some helpful advice via calls and text which is leaning towards the bearing cups not seating properly.

Unfortunately no daylight left. :(

Have you tried pulling on the end of the cv with multi grips? Sometimes the grease will hydraulic lock the cv a touch in and pulling on it gets it the last little bit!
Also try giving the brake disc a good hit(hands at 9 and 3) to make sure the bearings are seated all the way in.

If I pulled the CV and harder it would cum!

Havent abused the brake rotor on. But may be worth a shot with the new seals.

Is the hole in the end of the shaft threaded? If there is a hole that's thread get a bolt that fits and put it in and give it a tug while putting the cir clip on. If not u got other problems.

that guy wrote:you will find 99% of the time this happens the seal on the back of the spindle is not taped down properly.
have seen this plenty of times slip it off and make sure its on properly.
then if it still wont come out far enough its just a matter of working it until the circlip will go on as the seal is new it will need to compress slightly.

This. Sometimes if you're not careful putting the hub back on the stub axle you can fark the seal and then it jams and causes issues. Pull the hub and disc back off to be sure.

Turned out to be the seal on the back of the stub axle...that meets the CV bell. Was a brand new one with the spring (surrounding it) a little damaged. Thought nothing of it. But tapped everything I could and it was locked down fine. Changed the offending seal with another new one and made sure it went on properly before continuing the assembly.

Thanks for all the tips, I checked them all!