Snap ring dana 25 wont fit help

I am installing the dana 25 axle in my 48 cj2a and I cant get the driver side snap ring to clear and set in the groove with the drive flange installed. the passenger side went in easily and the shaft had plenty of endplay to get the snap ring on. but I cant get any endplay on the driver side at all.

I have tried pulling outward on the driver axle shaft and prying with pry bar and I cant get it to move far enough from the drive flange in order to allow me to install the snap ring.

the axle was completely torn down and inspected with new bearings in pinion, carrier and wheel bearings for one side only. all new kingpin bearings and cups and new king pins where pressed into the old king pin cap on one side only top and bottom.

can anyone tell me what I have to do to get the drivers side snap ring installed?

 

Did you adjust the shims for end play?

 

Perhaps the outward face of the shaft universal may be hitting the inner spindle bushing.

You did not indicate the particular type of axle shafts.
Nor did you specify which particular hub spindles.
See: http://z4.invisionfree.com/CJ3B_Bulletin_Board/index.php?showtopic=3064
Or search: RZEPPA SPICER BENDIX END FLOAT

 

No to the shims. I added and removed shims to adjust the pinion but the carrier I just reinstalled old original shim pack with new Timken bearings.

Sorry I forgot to put about what style shafts I have. originally before I tore it apart one side had a Spicer (u joint) style and the other had Bendix (with balls). both knuckles had the tag on the knuckle seal saying bendix so I assume bendix was original. my spicer u joint that was already in it was in good shape so I reused it and the other side I replaced with another spicer style off ebay from R&P 4WD. so now both sides are Spicer ujoint type.

Both side spindles got new Crown I think was the brand spindle bushings. the type that is in the spindle only that has the shoulder on it.

 

I'm guessing that this is the problem.
That goes double if they happen to be Ommix Adda spindle bushings.
It is very uncommon to have need for new spindle bushings unless they are obviously damaged.

Remove the spindle and inspect the replacement bushing for abnormal shaft contact.
Can you re-install the original spindle bushings ?

 

I can't remember the last time I even put snap rings back on an axle.

 

^^^ x2

 

x3
As long as they're the Spicer u-joint style shafts, the snap rings aren't really needed.

 

Good point. All I've ever run is the spicer style.

 

at least for now I have gotten the snap rings on. I ended up removing the drive flange gasket and used Permatex Ultra Black instead and that gave me barely enough room to install the snap ring. I think I threw away the old spindle bushings. I don't recall having this problem when I did the dana 25 in my 59 cj5 and I used the same new spindle bushings, mostly because I was installing so many new bearings and stuff I figured I would finish it out with all new stuff.