I'm tackling a rear axle rebuild and have gotten to installation of everything back into the axle but can't seem to get the rear pinion race in there. (The bigger one, towards the rear of the vehicle). This is an 1998 XJ 4x4 with 8.25 rear axle.

I've tried a race installer w/lots of hammering. I tried a slide hammer method, I tried sticking the bearing in the freezer then trying to install (w/race installer) but nothing gets it to fully seat and it really likes to to and get jammed up. We're really putting a lot of force and it just doesn't wanna go in. I can confirm it is the correct part #. Timken M802011

Our next thought was removing the axle and getting it on the press to try to press it in but before I go that route, maybe there's something I haven't tried.

If you measure the old race with the new one, is there a big difference?

Also, where did you get the parts from? Ebay or someplace reputable.

Finally, try another brand and see how that goes. It is not out of the question that you just got a part that is out of tolerance.

I got the parts from a Yukon kit I bought from Amazon. It sounds like they're pretty reputable but I haven't measured the races, I only checked their part numbers. I may try the freezing technique again if I can get it out of its current spot and it happens to be the same size.

I guess if you freeze the race you could also apply some heat with a heat gun to the axle housing hole for the race. And plenty of grease.

If it still gives you issues, I would try another brand.

I would suggest you may be getting it slightly cockeyed. I know you are technically not supposed to do this, but I have been doing this for forty+ years. Get a long alignment punch, grind off the point and use it to tap in one side at a time. I just set up a D44 using this method. Always has worked

I would compare the outside dia of the new and the old race,, any cheap digital calipers should tell you if there is a difference

I've had new in box parts, even from reputable sources, that were machined wrong. It is worth checking.

The 99 factory manual says on page 3-97:
INSTALLATION
(1) Apply Mopar Door Ease, or equivalent, stick lubricant to outside surface of bearing cup.
(2) Install the pinion rear bearing cup (Fig. 30) with Installer C-4308 and Driver Handle C–4171.
Ensure cup is correctly seated.

I would suggest you use a stone to get any burrs off of the edges inside the housing.

All bearings are within spec. Trying the freezing technique again and try 4.3 XJs technique.

If that doesn't work, I'm removing the axle and putting it on the press.