Jack.
I will hazard a guess....
The roller bearings that support the half shaft come in two different diameters (wrong and right). These are matched bearings and races. The race is found pressed over the inner half shaft and the bearing is located pressed into the swivel ball flange. If you have mixed and matched these parts it is likely the half shaft is hanging up prior to arriving at it correct position. This causes the half shaft to hang out too far as you describe.
If you need the right parts I have them in stock.
Alan Simpson
Rover Works B.C. Ltd
250-458-2447
