2010 Sportsman 850 Front Axle won't stay in differential
I have a 2010 850 and had to replace the front right axle. I went with a Rhino from SuperAtv. The problem I'm having is I can't keep the axle in the differential. I can hear the retainer clip "click" into place and I can't move the inner axle housing at all when on the jack. Stays seated in differential. I put everything back together, rotate the tire/wheel, turn the wheel left and right, etc. Occasionally I can turn the tire left and right quickly and the axle will disengage from the differential. When I take it off the jack and back it out of the garage, it disengages from the differential and I can move it in and out by hand, every time. I have also been able to move it into the diff by hand and hear the click. Then it's tight again until I run the machine again. Go 20 feet and check again and it's loose again. SuperATV replaced the first axle that I had this problem with and I'm having it again with the second one. They have been helpful but I don't know if it's a problem with the axle or something else.
I noticed I had a worn out ball joint on the bottom arm so I bought a new one and replace that today. Very little play in the front right now and it didn't help at all.
I've researched this issue on the web but mainly found things about this happening on Rangers and on the rear. I still have the original axle on the other side. Maybe the new axle is a little long and is being pushed out by the other axle? Should there be a space inside the diff between the two axles? I can't tell if they are touching or not.
Any suggestions? I really need the machine running - duck season is getting ready to break loose!