Quote Originally Posted by p_justin13 View Post
in the process of cleaning the hell out of now to even see if will dry fit. Is it possible parts of the splines could have sheered off and that could be holding it out. Had some debris come out but nothing to big or unexpected
It's possible I guess, but I'd suggest waiting till later to consider that as worst case scenario type stuff. Had you added much/any grease to that cv-joint dust seal that fits to the back of the spindle assembly? A lot of grease in that dust seal could cause the same type of hydraulic lock situation that could prevent those two pieces from fitting together.

Short of that happening, I'd be inclined to go with VXorado and say that it may just be a matter of turning the hub assembly this way or that until the splines on the cv axle line up with the splines on the hub flange. (assuming that the axle is currently coming all the way through the hub assembly that is).