Before commenting, please at least read my whole post.

First of all, most of the rear end of the car is taken apart right now (still on jackstands). So driving or towing the car to a shop is out of the question. My axles need to be popped back in before the car can be moved / driven.

Ok here’s the deal…

Few weeks ago started noticing what felt like a slipping clutch while taking off in 1st and also hard acceleration while turning.

Found out that BOTH my rear axles were loose to the point where I could move them in and out of the diff easily (but not all the way)

Drained my rear diff only to find metal shards all over the magnetic plug.

Removed both rear axles from the diff and found out the drivers side had a bit of damage on the end of the splines where they go into the diff.

Found out the axles were slipping in and out of the diff because they popped out past the point of where the metal retaining C clip is inside the diff.

Removed the rear diff, opened it up, flushed it out, removed the old C clips inside the differential.

Used a triangle file to clean up the splines on the driver side axle so it could be reinstalled.

Ordered brand new OEM clips from subaruparts.com pn# 28033FA000 (no dealerships locally stock these)

Installed the new clips on the ends of my rear axles.

I’ve tried for the past two nights to get the axles to go back in with no luck at all, they just won’t go in past the point of where the clip is. I’m using 99RS axles and ordred clips for a 99RS so they should just go in right? But they don’t.

Used a combination of a rubber mallet and a wood block with sledge hammer to pop the axles back in, no luck. Wiggled the axles while trying to hit them in, still no luck. (The axle nut is unbolted btw)

I’ll pay someone $100 if they can come over to my house and help manage to get my axles popped back into my diff all the way to where the clip is locking them in place.

My only other choice is to remove my rear diff and bring it with both the axles to GST or SE so they can solve the problem for me. (since I can’t move the car)

Full thread / pics on this can be found here: http://www.rs25.com/forums/f8/t12034...-happened.html

Please let me know if you can help out, PM me or just call my cell phone.. thanks.

Jeff
5105525122

 

Sent you an SMS.

 

Tools required:
Rubber Mallet (Large)
block of wood (2)

 

^ Been there done that already =/

 

I snapped a rear axle clean off at both boots. I don't remember the reinstall being this hard. Then again the fiancée at the time was the one that uninstalled/reinstalled on the floor of the garage with my supervision.

Something is buggered up inside of your diff from the first *pop-out* of the axles.

 

have you tried to ask on Nasioc or look up the Subaru tech manuals? I was working on those on a friend's WRX and I remember we also used a floor jack to help us out and blocks of wood. I wasn't under the car but I remember a lot wiggling