I had upper and lower ball joints installed on my 04.5 a couple of days ago. Went in for a wheel alignment and they could not do it because the lower ball joint was moving where it should be pressed into the axle. Do I need a new axle or can I shim this on the top or bottom where the ball joint meets the axle. What the alignment guy said might be worth a shot is to peen up the ball joint with a punch to make it a little rougher so when it is pressed in it might not move. Or does anyone make an oversized ball joint? I saw it with my own 2 eyes what he was describing.....

 

Was there ever any reaming done to your front end to fit differant ball joints?

From the way I read your post, it sounds like the hole is not tapered? Is that right?

 

they should fit tight, makes me wonder if its the right ball joint, not sure if the older dana 60 front axles are the same part number if it they are a tad smaller in size but thats not good.

 

I think this is my 5th set of ball joints, so maybe after so many removals and installs it is getting worn out! Taking it back to the guy who did the install tomorrow....

 

It shouldn't matter how many time you pull them. The tierod ends should have a taper that matches the spindle. It sounds like your tierods end may not be the correct ones.

 

I am having issues with the lower ball joint where there is no taper where it is pressed into the axle......