Front differential carrier backing out

[clowntrigger]

I have a 2002 996 C4. I replaced the front right cv boot. While mating the axle shaft to the carrier (or joint flange, see #2 below), the carrier pulled out of the differential. I pushed/banged it back in with a dead blow and all seemed well. After a few days, I noticed the car was leaking in the front. I put it on stands and saw the carrier had backed out again. I pulled the front axle and went through the same procedure. Another week and same results. I've got the front axle out again. The circlip (#4 below) on mine is not a full circle. Did I damage the circlip and need to replace it? Should the carrier only come out of the differential if the differential is dropped and disassembled?

Here's what mine looks like.

Any help would be appreciated.

[wvicary]

The circlip looks fine but should stand proud of the splined area. I have spread them in the past with good results but don't over do it or you'll have problems removing the flange if needed. It should also seat home in the differential with an audible click. Inspect the seal carefully for damage.

[rb101]

The shaft just pops out with a bit of force, I think your circlip has pasted it's useful life, it looks too compressed and should be replaced.