1. Inspection and Preparation:
* Damage Assessment: Carefully inspect the axle, transmission, and surrounding components for any damage caused by prying. Bent axles, damaged transmission internals, or broken parts will make reinstallation impossible or highly problematic. If there's damage, professional repair is likely necessary.
* Cleanliness: Clean all mating surfaces of the axle and the transmission thoroughly. Grease, dirt, and debris will hinder proper seating.
* Lubrication: Apply a generous amount of high-quality grease to the axle splines and the transmission input shaft.
2. Alignment is Key:
* Correct Orientation: Ensure the axle is oriented correctly. There might be slight variations in how it fits.
* Guide the Axle: Use your hands to carefully guide the axle into the transmission. Try to start it by aligning the splines as accurately as possible. Don't force it at any stage.
3. Reinstallation Techniques:
* Gentle Pushing: Once aligned, use firm, even pressure to push the axle into the transmission. Avoid using any sharp or prying tools. Your hands or a soft mallet (wrapped in cloth to protect the axle) are the best tools here.
* Patience: This might take some time and patience. The splines need to align perfectly; forcing it could damage the transmission or the axle.
* Impacting (use with extreme caution): If gentle pushing isn't working, you might try carefully using a soft-faced hammer to gently tap the axle into place. Again, protect the axle and transmission. Apply the impact directly and evenly on the end of the axle, not the side.
* Transmission Jack (if available): Having a transmission jack is beneficial to support the transmission if you're working underneath the car. This lets you maneuver things a little more easily while keeping the transmission in place.
4. Verification:
* Secure Fit: Once the axle is fully seated, it should be snug and there should be no play.
Important Considerations:
* Professional Help: If you're uncomfortable with this procedure, or if you've already damaged something, it's best to take the car to a qualified mechanic. Improperly reinstalling the axle can lead to serious damage to the transmission or axle.
* Workshop Manual: If possible, find a workshop manual specific to your 1996 Ford Aspire. These manuals often provide detailed instructions and diagrams that can be incredibly helpful.
Remember, forcing things usually leads to more problems. Patience, careful alignment, and the right tools are essential for success. If you encounter significant resistance, stop and reconsider your approach. It’s better to seek professional assistance than to risk further damage.
