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« on: May 21, 2007, 04:00:51 pm »
Andy,
Put me down in the jiggling/wiggling section of car maintenance.
MG Mark is probably correct. However try getting someone else (unless you have very long arms) to rotate the opposing wheel, while you try an insert the half shaft.
If that fails go with Mark's idea and try rotating the prop shaft, maybe by putting a big screwdriver in the universal joint. Make sure it is out of gear. You could also try stopping the opposite wheel.
Is the half shaft dropping in the axle tube, while you are trying to insert it? Can you try an lift it a little.
I am surprised you can file hardened steel. Did you use an angle grinder?
Good luck. Open a few beers, chat with a few mates, it will go in when relaxed.
Dickiex