This is an old thread, but it sounds like you are having the same issue. I replied before and was confounded with it back then.

However, as I think about it now, I am wondering if my issue at the time was the retaining ring on the splines. As it turns out the orientation of the ring can matter. This short video describes this trick. I thought I'd post it in case you or others might find it useful.

 

thats good,i do have a note for future reference...i often watch wrenching with Kenny...did you know he just retired?

 

Believe me I checked everything before i condemned the seal. The Retaining ring is the first thing I thought and checked. I removed it. Tried to reinsert the axle through the seal, without the retaining ring. The axle still would not go past a quarter inch or so. So I thought my new inner bearing might be the problem in that the axle was butting against the new inner bearing, which was too small of a diameter, that's what I thought it could be anyway. I removed and destroyed my brand new seal so I could check the bearings inner diameter. The new axles outer diameter and spline were correct. Once I remove the seal, the new axle easily.slid right on through the bearing all the way down to where it would be seated, no effort whatsoever with the seal and retaining ring removed. The bearing had never been touched as the grease I put on it, was still in place. The axle never got past the seal even as far as the bearing and the axle was on the spline. So then, with the seal out, I put the retaining ring back in and was able to tap lightly on the axle and get it right past the retaining ring without a seal in place. The seals are being manufactured too tightly, and what is happening is the seal and the rubber on it creates a suction effect and the seals won't allow the axle to get all the way past, no matter how much lube and pounding with a hammer. I am working on a solution this weekend. Fortunately, I have a few other vehicles.I can drive in the meantime. I needed to take a little time away from the frustrating problem to think it over and research. I also went to several auto parts places this week, To look at other manufacturer seals, including the GM dealer, and it seems this is a new issue that has come up in the past few years regarding the seals being manufaxtured too tight. The GM dealer is aware of the issue. Since this is the only thread I can find on the web pertaining to the seal being too tight to allow the CV axle to pass all the way through, I will post my solution so that in the future others who might be running into this same issue will know what I did to work around it. Just so it is known, I am working on the passenger side of a 2000 4 door blazer LS 4x4, without higher wider package. I knew this was an old thread so I really appreciate you replying, but it is not the retaining ring. I am also an old pro mechanic with, I hate to admit my age, but more than forty years in the business. I am also now recently retired from shop work. I still work on my own Chevy's and jeep, and enjoy helping my family, friends and neighbors with there vehicle's.

 

Believe me I checked everything before i condemned the seal. The Retaining ring is the first thing I thought and checked. I removed it. Tried to reinsert the axle through the seal, without the retaining ring. The axle still would not go past a quarter inch or so. So I thought my new inner bearing might be the problem in that the axle was butting against the new inner bearing, which was too small of a diameter, that's what I thought it could be anyway. I removed and destroyed my brand new seal so I could check the bearings inner diameter. The new axles outer diameter and spline were correct. Once I remove the seal, the new axle easily.slid right on through the bearing all the way down to where it would be seated, no effort whatsoever with the seal and retaining ring removed. The bearing had never been touched as the grease I put on it, was still in place. The axle never got past the seal even as far as the bearing and the axle was on the spline. So then, with the seal out, I put the retaining ring back in and was able to tap lightly on the axle and get it right past the retaining ring without a seal in place. The seals are being manufactured too tightly, and what is happening is the seal and the rubber on it creates a suction effect and the seals won't allow the axle to get all the way past, no matter how much lube and pounding with a hammer. I am working on a solution this weekend. Fortunately, I have a few other vehicles.I can drive in the meantime. I needed to take a little time away from the frustrating problem to think it over and research. I also went to several auto parts places this week, To look at other manufacturer seals, including the GM dealer, and it seems this is a new issue that has come up in the past few years regarding the seals being manufaxtured too tight. The GM dealer is aware of the issue. Since this is the only thread I can find on the web pertaining to the seal being too tight to allow the CV axle to pass all the way through, I will post my solution so that in the future others who might be running into this same issue will know what I did to work around it. Just so it is known, I am working on the passenger side of a 2000 4 door blazer LS 4x4, without higher wider package. I knew this was an old thread so I really appreciate you replying, but it is not the retaining ring. I am also an old pro mechanic with, I hate to admit my age, but more than forty years in the business. I am also now recently retired from shop work. I still work on my own Chevy's and jeep, and enjoy helping my family, friends and neighbors with there vehicle's.

 

Dang, this really is a puzzler.

And, yes, let us know what you learn!

 

so i never changed a seal because they were not leaking, i was able to push it on,but it took two hands with that part sitting on the floor...its tight...and i can not turn/rotate it now...and oh by the way, i could never find a cv boot to fit that axel