So, installing a passenger side axle in a 2006 XC90. the outside end of the axle shaft that goes through the wheel hub...the spine coming out has two problems:
1) it doesn’t come out all the way; it should come out another 3/4" or so.
2) the axle bolt only partially screws in. It is about 1/2" from the hub.

So, even if I can fix #1, the bolt would still be ~1 1/4" sticking out.

Anyone have any ideas?

 

Did you compare your old and new axles before you tried to install it?

 

Unfortunately, that is not possible. I removed this same axle to do an alternator replacement (Grr...) so I don’t have anything to compare it to. Yet, I do know that it fit when I took it out.

Any other thoughts/ideas?

 

I would go back to square one, take the axle back out and put it back in. Since you aren't replacing a part, just reinstalling, I assume the issue would be somewhere in the installation. Also, the axle bolts are torque to yield, so they need to be replaced every time they are removed.