I just replaced the engine on my 2011 Honda fit. When I put the passenger side drive axle, I need about 1/3-1/2 of an inch on the upper hole on the strut to insert the bolt connecting wheel hub assembly. Looks like the axle is completely engaged and the dust cover is all the way in. I wonder if I should remove the ball joints connecting the wheel hub to the lower control arm and to the steering rod end, or should I just use the vise clamp to try to force the steering knuckle into the strut assembly?

 

Gsp is seen here. Ill take the wheel off and make a better pic later


Wheel is turned outside on the top

 

my guess is your axle is not in properly.

i havnt done them on the Fit yet, but i read they are troublesome to get back in. are u using the original axles and hub bearings? i ask because last year i replaced a front bearing (generic) and it was either not machined properly or was the wrong one (despite having the correct part number on box), and the axle didnt slide thru it completely.

the axles and spindles shouldnt take any brute force to get into place especially since your car doesnt look rusty.

 

Forgive me if this aint useful. The struts are fastened while preloaded. so, torqued while compressed all the way by a jack to simulate vehicle weight. I'd debate, if yer positive about your install (done struts but not the shaft) being correct, why not just unbolt the strut where necessary (provided you have the proper crow's foot to re-torque it, think its 14mm should the top need to come off/loose for your needs).
Can provide necessary service documents if this goes in line with your intuition.

 

The axle was removed from the other Honda Fit, I think it was 2012 model. I had to change a couple studs on the old spindle and got the whole piece pulled from the other car. I checked out, Honda fits 2009-2012 have exactly the same parts, so this should be no issue. However, when I removed the axle from the other car, the gears inside of the boot might have got disjoined and this could cause this 1/2 inch extra length. I'll see if I can spin the parts of the axle to get them back to the original state.

 

I probably can just dislocate the ball joints on the strut assembly to be able to put the steering knuckle in the place. I just don't want to force it in.

 

The drive shaft axle was pulled too hard when it was removed from the car on the junk yard and the connector inside of the boot got disjointed. Fit it back in and axle worked just fine. Thank you everybody!