I hope I never have to do that again!

Used my hydraulic press on the uppers, and did the lowers in situ with the tool from OTC. The lowers are now in many pieces.

 

Well done, you've got to feel accomplished. I did all 4 in situ and promised myself I would buy complete new control arms next time

 

I paid someone to do it ($80)...that was easier.

 

When I did my lowers, I couldn't even get them out with my 12 ton shop press... Ended up using a plasma cutter to blast a hole in the middle of them, then use an air hammer to break it to get it out of the control arm

 

Any ideas on getting the ball joints back in?

I did all 4 of mine two weeks ago while replacing the control arm bushings and could not get the lowers to seat all the way in despite using a big Snap-on clamp and impact.

They are not sitting too high, 3mm or enough to see the gap all the way around. I have driven the car on and off and looked again but they still haven't moved.

Aside from taking everything apart and boring the hole any ideas on how to get them to settle in more?

 

3mm is about how far they go if (this is hard to describe) if the press is stopping them from going past flush at the top. I had to buy an extra cup for the press. Whatever you use must be able to slide over the OD of the balljoint.

Could that be the problem?

 

Not the problem. No clearance issues, just too tight of a fit.

I'm afraid taking them out and running some emory cloth around the outside of ball joints and inside the control arm may be the only option. Likely the new parts will get destroyed taking them out and I'll do the job twice and cost twice as much.........

 

I regret to inform you that I think the solution is to take the arms to a shop with a serious press.

I've noticed myself that the last few mm are the hardest. I think your clamp just doesn't have enough oooomph.

 

Makes the job easier if you warm up the arm in the oven and have the ball joints in the freezer overnight and only take them out just before you are
about to fit them.
making sure the hole in the arm is clean....no lubricants needed and they should push home fully seated. ;o)