While tapping my new cv joint onto the shaft, like an idiot I didn't put the castle nut on first thus slightly bending some of the threads on the end.

My question now is: am I screwed or is there a trick to getting the castle nut started? Can I retap somehow? I still have the old cv chaft and the outer part with the shaft is good, it was the inside that was bad. Should I put the internals of the new cv into the old outer cv since those threads are still good? I am so sick of working on this thing....

 

A thread pitch file available at a lot of auto stores could solve the problem and clean up the threads,plus a lot of them have the thread pitch measuring tool,plus may have individual dies if needed. If no help there then an industrial supply house could help on individual dies to keep you from having to buy a complete tap and die set! One of the most complete in our state is Grainger Industrial Supply,not sure on your location. OPT

 

i have used a file as mentioned as well to fix the threads.

 

I use what some call a thread file. And I too have fixed an axle shaft thanks to a hammer happy brother-n-law. I have two of them which give me gives me the option of 16 different and most common sizes of SAE and metric bolts. Very handy to have and cost me around $10 each.