Searched a bit while here at work, but no joy...

On my 91, it's spat out the driver's side axle the last 2 times I've wheeled. It's a reman'd axle that I verified length on before install a little more than a year ago. I wheeled Uwharrie and had no trouble with it coming out. There is an Aussie locker in the front, but it's been there well over a year too. I took everything down over the last couple weeks and didn't see any reason for it to come out. I replaced the c-clip with an OE one and it was a biotch to get socked home. But once it was in there, a firm yank wouldn't dislodge it.

Anyway, the hour and a half ride up was uneventful. I ran Betty's Creek to Patterson Gap over to Tallulah River Rd, crossed the river and up over to Upper Hightower. Came back into Clayton on 76 and stopped at the Racetrac to fill up before heading home. Peeked under and saw wet on the inner joint. Sh!t... Not quite sure what elso would cause it to pop out...

Ideas?

You sure its not your seal on the diff? It is hard to believe your cv is walking out on you. When you get the entire thing put back together and your wheels on then try yanking on it then. Pulling on it when you 1st installing it is not a completely fair test until you have the other end in the hub and everything together.

The seal is new and the shaft's coming out enough to leak. I could here it click when it went what felt like all the way in and I was able to pull it and feel it move outward.

This is a huge Gen I problem as they age. My last Gen I did it no matter what on one side until I sold it. Seems a new clip works in the beggining, but eventually something else goes wrong. It should be resolvable, but I never nailed it down. The AZ boys might have a solution, as they have dealt with a lot of this issue.

Thanks Lloyd. Maybe one of them will have some insight...

Are the T-bars cranked and/or other mods done?

Someone should try shorting the Pass side shaft so it can slip in on the drivers side so that you can have bolt on axles for both sides. Hell, make the both like a chevy rear so you have a thick clip holding them in so it can't pop out. Down side is you would then have to remove the cover to pull them out, but hey no axles popping out then. Just musing of a un-normal mind.

Yes, t-bars are re-indexed 1 tooth and cranked. Running 35's also, which probably doesn't help matters, either.

How about simple mechanical wear on the inside of the spider gear the CV plugs in to? Wouldn't constant knocking against an edge naturally make a ramp where the C-clip is located?

Except that it's an Aussie locker that's real squared off and has maybe 75 miles of 4WD on it since install. I've been stewing on this and can't think of anything besides too much lift. The obvious fix is SAS, but that ain't happening with this truck...

This usually happens with the passenger side, the one with the half shaft. Never seen it on the drivers side. One thing to look at is the shims behind the circlip on the outer axle stub shaft where it goes through the hub. If you have shims in there, and your bars are cranked and bumpstops trimmed, you might want to remove the shims to allow the axle more free float and more travel in the direction of the diff. This could possible help.

Ensure you have the right circlip in your inner too.
At one time they were a different pt # for each side, but now have been superceded with a new part # which is same for each side