So, I have two pairs of upper/lower Dana Spicer Ball Joints, and take the front end apart today. Passenger side went without a hitch except the moron that owned the vehicle before me stripped BOTH caliper bolts. So... On to the drivers side. Ball joints came out easy, but oddly enough, the Dana Spicers just drop in. After some perusing at the local parts house, it looks as if the lower on the drivers side is slightly larger and is a Moog improved replacement that has splines cut in the sides (must slightly enlarge the opening when you put the lower in). The upper on that side is also enlarged, and even the Moog replacement wasn't large enough. I had to put the old upper back in, which, the shank that bolts to the hub is larger, so it doesn't like seating and also barely clears everything.

So, at this point... What are my options? It looks as if someone fscked up the "C" looking thing that the ball joints seat into (If you go here, they are the things to the very right of #26 in the diagram, http://ep.yimg.com/ca/I/yhst-3365240..._2212_40259246).

Anyone have any ideas on what to do here? I want this fixed right.

 

I'm scratching my head on how you can fix that. If it weren't a tapered hole, I'd consider welding it up and re-drilling the correct hole..but that would be a bugger with that taper. Best I can think of is to try to match the old joint up as best you can with something else, hopefully with a slightly shorter height.

 

I unfortunately have been throwing a more extreme idea around, and swapping the axle housing entirely out with one I know is good. I'm seeing it as my only viable option at this point that insures things are correct.

 

Weld a few good beads in it and try and press the spicer in just don't build up the weld alot then tack the balljoints in so they don't pop out, I have a friend that has done this and it worked fine still running it lol