Thanks all....managed to get it back in only after taking the cv boot off to inspect. It is a total pain in the back side, this is the second time it has happened and the same car aswell. :P
Hope this will help others out,
What we found out is that the 3 x bearing on the FD has a more tighter fit ( more sharper edges) then the B16a shaft (more rounder edges). So to put it back in you need to be very exact putting it back into the socket.
The slightest angle on the bearing and it wont pop in. Took us awhile even with out the cv boot. So the maybe the best way is to try to push the bearing under the CV Boot more flat to slid into the hub.
And get the shaft inline with the socket (hub) as much as possible
Hope this pic will help people understand what is happening and how to pop the F**K shaft back in.
Thanks guys and Have fun



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