Front differential and half shafts

dna9656 · October 11

Vehicle: '04 ZR5 4 door, 4X4 S 10, (I might have the ZR part wrong, I have other more important issues to think about right now)
I replaced the timing chain sprockets and tensioner, that's a whole lot more work than on a small block. I ended up removing everything under the engine, center link, tie rods, 1/2 shafts, knuckles, the brakes to get the oil pan down. GM prefers you place the oil pan on the T-cover/oil pan gasket nexus vs. dropping the pan a little (IMHE) by loosening the first 3 bolts (from the front) a bit and pry down on the pan and slip the T-cover in place, I tried that, ain't no way that is going to happen with the other bolts not loosened there are 2 more bolts accessible on the pan proper, the last 2 are accessed through the bell housing. My problem with this is once a gasket seal is disturbed you can forget about it's sealing any more. Especially where there is RTV involved. Maybe I'm wrong, maybe you guys have had good experiences with this method, I don't trust it.
So, anyway I got it put back together with no leaks! I am replacing the 1/2 shafts on both sides, I found one (the drivers side) had a tear in it and the grease inside the boot had been flung out and now coated the inner fender and parts of the control arms, not knowing how old they were and the truck was all torn apart I decided to replace both sides. While I had it out there had been a small tranny fluid leak in the past, the front axle and surrounding areas were oily and dirty. I had the front diff out so I replaced the shaft seals and cleaned the case, rotating to around to get it all cleaned. Its tricky to reinstall if you don't pay attention to the how to given in the GM manual and you'll still need a small pry bar to rotate it clockwise into position. I did all that In Accordance With (IAW) GM instructions.
Problem: The new half shafts will not install. The MFR's video says "a few love taps with a rubber mallet" will pop them into their home, no, it won't, not even a little high grade persuasion will make either side go in. I emailed the MFR and they offer no help but a return refund.
Suspicion: Rotating the diff while cleaning it allowed some internal part(s) to more and block the shafts from being fully inserted. What do you folks think?
TIA

asilverblazer · October 16

On 10/11/2024 at 2:44 PM, dna9656 said:

...Problem: The new half shafts will not install. The MFR's video says "a few love taps with a rubber mallet" will pop them into their home, no, it won't, not even a little high grade persuasion will make either side go in.
Suspicion: Rotating the diff while cleaning it allowed some internal part(s) to more and block the shafts from being fully inserted. What do you folks think?

Doesn't seem likely, can you look inside and see any obstructions?

Can you compare new parts to the old ones?

Will the old ones install?