Originally Posted by
dojj
It shouldn't have come out of the hub side at all, only the other side
Which makes me think the locking clip hasn't gone in all the way which means the shaft isn't seated properly in the outer cv which has forced it further in
I'd be taking it apart from the outer cv boot to have a good look before doing anything else at this time
I think you might have misunderstood. The entire shaft including intermediate shaft and cv joint was removed as one piece, as you would do if you were replacing a wheel bearing.
I took the shaft apart last night and all of the ball bearings are seated nice, there is plenty of cv grease, and the shaft is seated into the cv joint as far as it can go. After rebuilding I took it out for a drive and it sounds better, a lot better, but there is still a slight knock on absolute full lock left.