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Discussion Starter #1
So I am running a hp d44 from a 79 ford f250 under my xj and the other day I was installing new balljoints and the upper balljoint would slip out of the steering knuckle. I have a heard a couple of different things that it could be. One is that the ears on the steering knuckle could be warped and a solution would be to just buy a new knuckle, second was that I might not have torqued the upper ball joint screw ( that little threaded insert that you install in the C knuckle before installing the upper ball joint) to the right amount, or three which I am dreding would be that the C knuckle has bent one way or another and when ever i tighten the lower one in and then tighten the upper, the upper starts to get pushed out. does anyone have any ideas on this and if it is the dreded #3 then how would I go along finding out which way to heat up and bend the C knuckle back to the correct spot. thanks for any help.
 

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So the problem is that the upper balljoint body is loose in the steering knuckle? How did you install it? Did you adjust the tapered sleeve in the inner C?

I highly doubt your inner C is hosed, you may have boogered up the knuckle and just need to replace that. What size tires, and how much backspacing do your wheels have?
 

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geepxj said:
So I am running a hp d44 from a 79 ford f250 under my xj and the other day I was installing new balljoints and the upper balljoint would slip out of the steering knuckle. I have a heard a couple of different things that it could be. One is that the ears on the steering knuckle could be warped and a solution would be to just buy a new knuckle, second was that I might not have torqued the upper ball joint screw ( that little threaded insert that you install in the C knuckle before installing the upper ball joint) to the right amount, or three which I am dreding would be that the C knuckle has bent one way or another and when ever i tighten the lower one in and then tighten the upper, the upper starts to get pushed out. does anyone have any ideas on this and if it is the dreded #3 then how would I go along finding out which way to heat up and bend the C knuckle back to the correct spot. thanks for any help.
It sounds to me based on your description that your knuckle is wore out. I'd suggest replacing it...that balljoint should be a tight, press fit in the knuckle, no slop allowed, if it has slop like that and you're running big tires THIS IS A MAJOR SAFETY ISSUE. I wouldn't even recommending driving it at all until you can get this fixed.

David
 

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wow. try adjusting the tapered sleeve, if its beyond the limits of said sleeve, something's bent... should be obvious which is bent, upon visual inspection
 

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Discussion Starter #7
so i think i will reinstall the threaded insert and try to reinstall the ball joint and if that doesnt work then i will go look for another steering knuckle and go step by step from there.
 

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Both upper and lower ball joints should be a press fit into the knuckle. If they are anything less than tight in the knuckle then more than likely your knuckle is bad and should be replaced.
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