I'm replacing the front passenger CV axle in mine and having a time as well. Disassembled it 3 times so far and I think the problem is the CV axle I got from Oreilly, this one:
http://www.oreillyauto.com/site/c/d...ck=Search_01424_1416833_-1&pt=01424&ppt=C0362
After the first install, got everything back on, filled the tranny and ran out of gear oil, let it sit overnight so I could get more, next day I get under there and it's been leaking from the CV axle/tranny hole. I figure it's just not in there good so I pound on it as best I can in that position. Then I disassemble it all and pound on it some more in a straight position, but it still just spins in the tranny and doesn't catch the gear teeth. Reassemble thinking maybe once I get it back together and running it'll seat properly, but everythings spinning.
Then I remember seeing something on another forum about CV axles being the wrong diameter or not having the right number of teeth, so I disassemble again, and the new CV axle is a smaller diameter than the original.
Will be trying to work this out with Oreilly tomorrow as I'm sposed to take it on a trip this weekend.
Will see out it goes.