Front hub troubles

[Sutek]

Landrover 110 300 Tdi 1999.

Hello, I’m replacing my front diff and have run into a problem. I’ve put the hub on and tightened the bearing nuts to spec. I had to buy two new nuts as one was destroyed getting it out (cold chisel). I noticed that there is very little thread showing past the outer locking nut. I measured, and the new nuts are slightly thicker than the originals. I can’t see it being a problem though, as there is still safe thread distance past the nut.
The issue I’m having, is that when I put the outer flange on, I can’t get the shaft far enough through to put the circlip on. Even without the spacers.
Does anyone have any ideas, as to where I could have lost this length and how to get it back? I’m afraid I might have to pull the whole thing off again but really don’t want to do that unless I absolutely have to.

[Grappler]

Did you replace the wheel bearings? If so check the bearing shells are pressed home.
Also I recall there are a variety of shim washers available to adjust the end float of the drive shaft/circlip, but you cant fit clip even with no shims.
The drive flange OEM paper gaskets are thin, and the aftermarket gaskets are much thicker. That could account for a little loss of end float

[Sutek]

Thanks Grappler, I was afraid it might be that. I guess I just wanted to make sure I didn’t miss something simpler. I’ll pull it apart and check.😃👍
😡 Didn't wanna do that, again !

[DazzaTD5]

Thanks Grappler, I was afraid it might be that. I guess I just wanted to make sure I didn’t miss something simpler. I’ll pull it apart and check.😃👍
😡 Didn't wanna do that, again !

before you pull it apart again....

*does the half shaft (the axle spline) rotate freely? (put your drive flange the opposite way round so it engages into the splines and turn it, if it turns freely all good)
*look at the end of the half shaft you will see there is an internal thread, wind a bolt into it and pull the half shaft out, you will see there is a reasonable amount of outward movement.
*so normally once the drive flange is bolted on i use a slide hammer with a thread on the end and move the half shaft out, there will be more than enough movement to put the circlip on the end.

*if the half shaft does not turn freely it means you have jammed the half shaft into the stub axle when you fitted it.

[POD]

Yes you usually have to pull the axle out a bit once the drive flange is pushed on. I usually use a pair of circlip pliers in the centre hole to tug it out a bit.