Half shaft problem.

Anyone got an answer to this problem I have at the moment. I have just completed replacing my 90 swivel seals. on completion I fitted the driving member flange I find I cannot get the circlip on the halfshaft with the original shims that came off of it. Only a couple of thou out but how can the endplay gap have altered when all the same parts are fitted. I know I may have to measure the endplay again and buy some different shims, But cannot see why.

The axle is fully floating it'll come out a smidge if you pull it, I just done it on my Rangie this week after I smashed a CV joint to pieces.

Thanks for reply but I am pulling the shaft out as far as it will go and can hear clonk of the metal reaching its extreme outer movement. Sure is a mystery this one. I am informed that the clearance is crucial so I must get it solved somehow.