2G Front LCA and Axle length problem

[Verdant]

I don't believe it should matter but these parts are currently installed. Volk front lower control arms, JDM Galant knuckles.

I tried reading through all the maintenance manuals, and the drivetrain tech artices, and watched multiple youtube videos, including jafro's videos on rebuilding axles and installation. I also just disassembled the axle and re-greased before trying to install, but I assume I put it together wrong?

I've recently been putting together the front suspension on my GSX and while trying to install the lower control arm and driver side axle, they won't fit together. While the driver side axle is installed the knuckle is pushed too far out for the LCA to meet. While the LCA is installed the axle can't twist enough to clear, even while trying to swing the knuckle around the wheel well. The half shaft holes also line up with their holes into the block.

What am I missing?

 

[FIBA M - EC17PSE]

Its abit tricky to read it exactly right but pics may help also. But i think i got rhe general idea from it. Are you sure the axle is seated in the gearbox ok and the halfshaft splines are fully seated in the outer axle? The galant knuckle does not alter anything in fitment apart from the caliper mountings. I have also confirmed this in a 3D scan due to another mythical saying once before.

While i dont want to say its installer error have you confirmed your seating everything and have made the volk arms the same length as oem before installing them?

Also can you install it with the compression arm off and moving around freely?

If it worked before and not now then you might have over looked something or skipped something. The arms are a direct swap and can be done with ease on the car so when you removed everything fitment should still go back as normal. Double check your work and they both seat together as the outer axle CV needs a firm push to lock in the retaining ring, if its jamming half way that might be enough to cause a weird issue of not fitting right

 

[Verdant]

I will have to go over everything once again I guess. I pulled the axle fully out and knocked it together a couple times to check if it was fully seated, nothing changed and I was unable to pull any of the shafts apart by hand.

Tried without compression arm attached and was a no go, I've also checked the length of the volk arms to stock arms with hex keys and they're on the money.

I was curious, are the driver and passenger outer cups different lenghts? Maybe I swapped them? I will be pulling everything out again after work and try to comb through my mess.

I pushed the axle in as far into the gearbox as I could get, but I didn't hear a click if I should have. I assumed it was all the way in since the half shaft bolt holes lined up?

 

[Verdant]

You were right! I knocked the outer cup off to find a mangled retaining ring.

Where can you find a replacement for these? Can't seem to find them online, and the ones with boot kits didn't fit