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I'm in the process of servicing my M38 rear axles. After taking everything apart I had the new bearings pressed onto the shafts. I then greased everything up, installed the new inner oil seal in the axle housing and then installed the shorter of the two axles tapping the bearing cone and cup into place. No problem so far. I flip the housing around, do the inner seal, grease everything up and slide the long axle shaft in. The problem is that after the shaft seats in the differential, the bearing cone is sticking out about a quarter inch beyond the face of the axle housing flange so the bearing cone can't seat inside the housing. I never touched the differential other than to replace the cover gasket. I am totally stumped on what could be holding this up. What am I missing here? Any suggestions will be appreciated.

Just went out and looked at this again. Is this possibly correct? I don't remember this sticking out like this when I took it apart. I took some pictures but they were of the other side.

Yes correct! There are shims that go on each side over the bearing race and then the heavy washer. These sandwich between the brake backing plate and the axle housing. When pulled up tight, the ends of the two axles have ( I think around 7-10 thousands clearance ) Check the book for that figure. Don't put the heavy washer on first and then the shims, notice the inside hole is different diameter. John

Thanks Oilleaker1! Your quick response kept we working today. It was the first day I've had to work on the jeep for a while and it was not raining for a change.