I have a 2006 MC SS that I am trying to replace the passenger side CV axle. I one I ordered will not go into the transmission all the way, I even took the clip off it to see if that what was keeping it from going in all the way, even with the clip off it still will not go in. When Has anyone out here had this problem and if so what was done to fix it

 

How does it compare to the one you removed? Same spline OD, length, and count? Are the splines going in at all?

Its possible they shipped you a non HD axle. Although the non HD is smaller diameter, the spline count is different so it may not go all in. IIRC its 34 vs 39 splines

The other possibility is manufacturer error (assuming the car's diff isn't destroyed of course).

 

Mine is an 02, don't know if that will make a difference. But, yes years ago at a Super Chevy Show at Fontana, Ca. I lost a passenger side cv axle on the track. Found a local motorhead shop (referral from a guy at the track), they installed a new axle, but could not get it to seat and kept leaking fluid. They ended up cutting off the tip of the new axle enough to permit it to slip / lock into place. Drove back to Utah no problems. As to if it was a Non hd or HD I dont recall, been 15 years or so, but I think it was all upgraded to HD by this point. Guess you can count the splines on your new / versus old, if the same and not inserting all the way, chop it... if you be in a time crunch and all.

 

The smaller diameter, non-HD axle will go in all the way, just not seat. I just went thru this a couple months ago.

EDIT: At the time I also thought it was not going in all the way. I had to really get in there and examine to see that it was.