92 Accord auto.

Ideas? This has happened twice in about 5K after being good for about 20K.

 

Is it happening on the same side?

If so, pull the axle out, check the wheel bearing, ball joints, look for bent control arms, check the axle to see if the C-Clip on the shaft is how it should be, and if everything is good, try changing the axle to a different one.

 

Check the c-clip on the inboard stub shaft. The splined part that it goes into the tranny housing; there's a c-clip at the end of the shaft to help it lock into place once its seated.

 

The C clip is still there. I put it back in with a block of wood and a rubber mallet - probably better than I did the last time when I had to do it in a parking lot with a pry bar. If it comes out again, I will get a new one - this one has lifetime replacement.

How do you all put them in? I just take a block of wood and tap/beat them in with a mallet. Is there a better way? This has always worked before until now.

 

It usually just goes into place with a few nice pushes. Sometime I would put the end inside the front knuckle with the axle nut to hold it in place and beat it with a Hammer. It usually goes into place pretty well.

 

Agreed. Should snap into place, now pulling them out can be a right pain.

I have the following dimensions for '90-'93 Accord half shafts.
Left 32.6-32.8" (836.7-841.7mm)
Right 18.6-18.8" (478.7-483.7mm)
This measurement is taken from compressing then extending the inner CV and placing it in between.
Should be what the axle rests at when relaxed on a bench.
Measurements are taken from end to end, excluding the splined shaft.
From bottom of inner cup, to face of outer CV.

Its possible you were given a unit in the wrong box.