Need Guidance: Ball Joint Issue

[jhackathorne]

Hello all... so during my install of the Teraflex HD Ball Joints, I managed to partially crush the zirk fitting screw hole and now cannot get the zirks installed since they are out of round. One photo shows how it is partially crushed in and the second shows as it should be. I am hoping I don't have to remove them and there is some solution.... Tagging a couple of guys I know who have loads of experience in wrenching.

@chevymitchell
@Roky

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[Wolfslash16]

That's not bad at all. While not ideal, the opening doesn't appear to be broken/cracked, so you should be good to fix that. I'd take a screw driver (something round) just smaller than that opening and then lightly pry up on it push it back into shape.

 

[chevymitchell]

That's not bad at all. While not ideal, the opening doesn't appear to be broken/cracked, so you should be good to fix that. I'd take a screw driver (something round) just smaller than that opening and then lightly pry up on it push it back into shape.

What he said ^.

I would use a tapered punch and tap it with a small hammer until it’s round again. Then tap the threads.

 

[jhackathorne]

What he said ^.

I would use a tapered punch and tap it with a small hammer until it’s round again. Then tap the threads.

Thanks @chevymitchell and @Wolfslash16! I will give that a shot.

 

[jhackathorne]

Well... that sucks, Looks like I somehow cross threaded the lower castle nut on the drivers side and cannot get it off. Any ideas on that???!!!! I am never doing ball joints again! I know that!

@chevymitchell

 

[Roky]

If you can’t fix it, plug it or cap it, I think you can get it greased with the one zerk…

 

[roaniecowpony]

What he said ^.

I would use a tapered punch and tap it with a small hammer until it’s round again. Then tap the threads.

Having been a machinist in a former life and shop owner, I've seen a lot of damaged stuff. The tapered punch idea should work to round out the hole, but at the price of the threads. Tapping the threads again should fix that right up.

The tap size of zerks can vary, but my recollection is that they are very commonly 1/4-28. But probably should call Teraflex. 1/4-28 is a common size for fine thread bolts.

 

[jhackathorne]

If you can’t fix it, plug it or cap it, I think you can get it greased with the one zerk…

Hopefully the tap/rethread will work when I get there. I didn't mention that both zirks on both uppers are crushed. So fingers crossed that will work.

Any ideas on the cross threaded lower ball joint castle nut? I am guessing I am going to have to remove it and replace that ball joint. But I can't even get the castle nut off to remove it if I wanted to.

 

[roaniecowpony]

Well... that sucks, Looks like I somehow cross threaded the lower castle nut on the drivers side and cannot get it off. Any ideas on that???!!!! I am never doing ball joints again! I know that!

@chevymitchell

Try an impact gun first. You'll probably have to use an universal joint to get offset. If that doesn't work, you can split the nut with a nut splitter or cut it with a dremel/cutoff wheel until it is close to the threads and use a chisile to split it the rest of the way.

 

[roaniecowpony]

Also, if you can clamp the knuckle up tight on the taper of the balljoint, the taper will help with some friction to hold the ball stud from rotating.

 

[Roky]

Hopefully the tap/rethread will work when I get there. I didn't mention that both zirks on both uppers are crushed. So fingers crossed that will work.

Any ideas on the cross threaded lower ball joint castle nut? I am guessing I am going to have to remove it and replace that ball joint. But I can't even get the castle nut off to remove it if I wanted to.

If you can’t get it with an impact, you’ll have to cut the nut, if you’re careful you might be able to just get another nut. You might be able to run a die over the stud to clean up the threads depending on severity of the damage…..

 

[jhackathorne]

Try an impact gun first. You'll probably have to use an universal joint to get offset. If that doesn't work, you can split the nut with a nut splitter or cut it with a dremel/cutoff wheel until it is close to the threads and use a chisile to split it the rest of the way.

Tried the impact gun and no luck there. It just spins. Looks like I'll be cutting the nut off. Hoping the die will clean it up and I don't need to remove the ball joint again and replace it. Ugh. @Roky

Thanks for the tips guys.

 

[roaniecowpony]

Don't cut into the ball stud threads, split with a chisel the last bit.

 

[dpike]

So was the initial damage done from pressing the ball joint into place ?

 

[jhackathorne]

So was the initial damage done from pressing the ball joint into place ?

Yes, it was. I am guessing I just had the wrong part for the top press and it caused slight damage to the zirk fitting.

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