I can't get the half axle to go all the way back in the trans. When I took the circlip off, it does go in. Now the circlip is stretched and there is no way the axle will go in all the way with it back on. Do I leave it off, get a new clip from the dealer or buy a new/rebuilt axle?

 

I unspread the circlip and put it on over the end. However when I insert the axle it goes in until the circlip reaches the spline in the transmission. I tried the back out and slam and the tapping on the other end techniques. Any suggestions for something else to try?

 

Bending and rebending the circlip hasn't helped.

With a good flashlight, take a look inside the tranny. See if you can figure out if there's a best orientation for the circlip. Inspection camera would be better if you have one.

1. If they're available, buy a new Volvo OEM circlip.
2. Grease the splines and circlip.
3. If the drive shaft won't tap in, pull it out, rotate the drive shaft a couple of splines and try again. Repeat.

 

I got it! On a Toyota website someone said to position the circlip with the opening facing down and held in place with a little grease. And it worked with a little slide hammer action from the play in the joint.

 

Good job. It's always stuff like this that turns a three hour job into a three day ordeal. If you had to do it again now you know how to do it it would be no big deal.