Real Time Help- ARB install

[FJ60Cam]

I'm in the middle of an ARB install, and having trouble sliding the short side axle shaft into the splines of the ARB. It slides in and out of the factory diff like butter. The long side slides in and out of the ARB no problem.

I don't think that it's the axle shaft splines. Has anyone ever had a problem with the ARB splines being too tight?

I tried tapping it in, but almost couldn't get it back out. That wouldn't be a problem, but then it wouldn't lock the c-clips in.

Any help would be appreciated.

 

[Dynosoar]

Use a small triangular file and "clean" the splines on the diff side. With some gentle file work it will feel just right.

Dynosoar

 

[KLF]

This is gonna sound goofy, but it worked once for me with an e-locker: lock it, then unlock it again.

Told ya it will sound goofy...

 

[FJ60Cam]

The short axle shaft slides in and out of both sides of every differential I have laying around (cept for ARB one). The long side shaft slides in both sides of the ARB diff just fine.

I did swap the axle bearings too, is there any way this could be part of the problem?

 

[Dynosoar]

Then I would use the file on the splines of the short axle. Again nice and gentile don't file your way to China.

 

[FJ60Cam]

Thanks for the tip. I didn't want to file on it or force it if something else was the problem. After several rounds of light filing, it was still tight so I ended up pounding it in. To push it back to seat the c-clip, I tack welded (superglued) a 16mm impact socket to the long shaft, slid it in and tapped everything in place. Worked like a charm, except for the 15 minute fishing expedition to retrieve the socket.