I replaced both sides according to the manual, refilled the tranny and both sides slipped back out with a sickening "clunk". REplaced them again, got the nice solid click, but one half shaft seems like the CV joint is coming apart. These are both new. Did I miss something?

 

The CV assembly can be pulled apart. If you pulled on the axle to remove, it may have extended too far and been damaged. Repair of CV assy is possible but tedious. You might try asking for a replacement.

good luck

 

Also, did they give you the correct shaft? If they gave you the wrong one (too short) then it's possible the inboard joint is being pulled too far out.