Upper ball joint just pops out when tightening the bottom nut

[PureCaboose]

My son on replaced his ball joints yesterday on his 1996 XJ and when he tightens the lower ball joint the upper ball joint is forced up out of the housing. It was not easy to get it to go in and still needs the press the get it to fit in, but when the lower nut is tightened (not to torque) the upper ball joint is spring up and out of the housing?

Aside from the being the wrong ball joints (they looked identical to the old ones) any ideas? I have done a few ball joint replacements on our JK's and never had this issue. The other side went fine with no issues, just this side is not working as expected?

Greg

[NTRubicon]

Bent lower C perhaps. Check the opposite side with a ruler and see if the space between the Upper and Lower C is the same

Replacement might be required.

[PureCaboose]

I will go and measure, the old ball joints came out ok and the new ones are knurled on the side to account for a worn axle. The old ones were not knurled, kind of doing me head in at the moment as it the last thing I need to worry about at the moment..

[junglejuice]

Pics, we need pics....

[jaffazoom]

isn't the lower ball joint the one with adjustable sleeve to set the spacing for the top ball joint, seems 2000-2001 don't have it on the low pinion.

this link shows one with the sleeve
http://www.ebay.com.au/itm/JEEP-CHER...EAAOSwz2lXBace


hard to tell exactly which years had it.

[junglejuice]

I've not seen that sleeve before...

[jaffazoom]

here's a clip on youtube clearly shows it

You Tube

go to 6min35ish and it is clearly shown.

this is an 89 model.

my parts manual for a 99 model seems to show it.
my workshop manual for a 2001 model makes no mention of it.

some seller's that show the threaded sleeve or what ever it is called list it as fitting up to 99 others to 2001. I assume the ball joints are the same it's just whether your's has the sleeve or not.

Quite possibly it's only early diffs that have them and we never had them here?
I can't see the manufacturing process being good enough that you don't need them to avoid incorrect preload on either ball joint, the CV style diffs have shims to preload there knuckle bearing.

Guess its just a Jeep thing!