We have this issue with every set of drive shafts we refit. The trick we’ve found is to clean each channel on the spline with a small file, luckily we have one that fits perfect and removes any high spots.Okay, so whats the trick?
Squeezed the hub into bearing so it was all the way home. Bearing then felt tight laterally. "Encouraged" the shaft splines into the hub, with a block of wood and "tapping stick". Just can't quite get the shaft in far enough to get the nut started.
Yes both sets of splines were cleaned and greased.
Is there some magic clamp tool out there for squeezing the shaft into the hub?