I'm up to the re-assembly phase. Got the beefy snap ring back in place (a 12-pt 24mm deep socket makes a perfect driver). I put the whimpy snap ring back in place, but can't get the outer joint to slide over it. Is there a trick here? Maybe I just need a new one? I'm half-tempted to just remove the ring and use some red Loctite on the splines. If this thing starts making noise or rips another boot, I'll just go with a complete half-shaft any way. But I'd prefer to do it the right way.

Any BTDT advise appreciated....