Need Help With New Ball Joint Install

Supersporter40 · March 22, 2009

In the midst of swapping out the ball joints in both of my trucks. The 01 was a little tough to get them out but the replacements went back in no trouble at all.

The 02 is another story, got the top drivers out and since the hole is not round I started measuring to make sure I get things going the right way. My calipers measure consistantly a twelve thou interference fit. Both upeer Moog ball joints measure the same. I gave them a try but they will only go in about 1/8" and then stop.

I am not using the typical clamp but one of my Bessey clamps and various sleeves I made from the lathe. It is a heavy duty sliding J clamp I guess you'd call it. Capable of 2200 pounds clamp pressure there is not much can slow them down. However it gets so bloody tight the little voice in my head says you better stop before it blows off and takes my head with it.

It is going in straight.....will that $90 clamp really make much difference?

VMax2007 · March 22, 2009

.012" interference fit in steel is WAY too much. .001-.002" interference is typically pretty tight.

txab · March 22, 2009

Are you sure you got the correct replacement part? They make, for some vehicles, an oversize press-in ball joint for c-arms that have "loosened" up from wear and tear. This could be your situation

Supersporter40 · March 22, 2009

Thanks guys. The other ones for the 01 were only two thou over. Thought I was loosing my mind last night when they would not fit after the other truck went so well I was sure this would be a breeze.

Appreciate the help!

Noel

Supersporter40 · March 23, 2009

Got a bit of a shock today, called Federal Mogul and talked to a tech guy about these ball joints. They only make one size....... to which he said yes, they are that tight on purpose. He said get a bigger clamp. Holy crap! I hope my lowers don't split when I run that in.

Supersporter40 · March 29, 2009

In case anyone comes across this topic down the road........ we ended up buying an OTC press. The MOOG joints were pretty tight but they all four went in. Having the proper tool makes all the difference.

Gryphon · May 24, 2009

Wow, glad I found this post. I'm having the EXACT same issue right now with my 05 and we HAVE the OTC press.

Did you remove the upper control arm from the truck? We left it on thinking we could get away with it, but I swear we're going to break the ratchet before this damn thing is pressed in. We're measuring up to .015-.018" interference fit, which seems like WAY too much. We have an el cheapo ball joint that measures about the same as the OEM but I'd rather install the Moogs.

The part number I have is K6696, which a lot of places says fits 2500 and 3500HDs. Is it the same ball joint or did I get sold the wrong size? Please help, someone, soon. Front end is laying scattered in the driveway and I'd rather not have to drive my old man's Ford for a couple days.

5-0stank · May 24, 2009

I used Moog ball joints in my mustang when I replaced them, they were tight...but the c-clamp style tool helped a lot. That, and an impact.

Gryphon · May 25, 2009

So we came to the conclusion that we were sold the wrong ball joint. There is just no way something that is .015-.018 oversize would fit into that hole without breaking something, or stressing something so badly that it would eventually break. We bought another brand and it slid in perfectly, hell getting the rubber boot on was tougher.

So for posterity, 1999-2006 GMC Sierra 4x4 upper control arm ball joint from Moog - do NOT get the K6696!