CV Joint Assembly Question
 

Hi. I’m in the process of replacing a torn CV boot and have run into a problem.

I used a puller to remove the joint from the axle and removed the cup washer along with it. My axle seems to be an aftermarket replacement and the cup washer has a ridged inside diameter that matches the spline on the end of the shaft. The joint/washer was a real pain to get off even with a puller. The problem is the washer that came with the new boot kit is too large (slides past the stop) and I don’t see a way to get the original back on without damaging the shaft splines. The CV joint itself also looks like it doesn’t want to go back on.

Any ideas?

You did take out the circlip first, aye?

Yes.