I wonder if there could be a burr on the splines inside from possible previous damage at one time preventing the splines from simply lining up and slipping in place?
On one of my M37 trucks I had to remove a broken part of the end of an axle shaft that was still stuck in the splines of the differential. I believe I was able to cheat at removing it by taking out the other axle shaft on the opposite side and simply send a rod down the axle housing and pop it out but not sure if the carrier differential is open to be able to do this or not. It’s been too long for me to remember!
Anyways, maybe helps with your dilemma.
Regards,Derk
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1942 Ford universal carrier Mk 1
1943 Ford 60 cwt long CMP ambulance
1943 Ford GPW 1/4 ton stretcher jeep
1943 Bantam T-3 1/4 ton trailer
BSA folding airborne bicycle ser#R5325 (early)
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