Jaguar Repair: 84 XJ6 ball joints, lower ball joints, spindle assembly

Question
Howard,
I was attempting to replace my front lower ball joints tonight, but it seems the ball pins are hopelessly seized in the control arms. I have used a separator fork (broke it, had it ten years and countless jobs) broke a c-clamp, have applied torch to the left control arm for nearly 5 minutes solid, no effect, have even placed a socket and extension on the nut, threaded just so it is flush with the top of the pin, and beat with an 8 lb sledge hammer - will not budge. What would you do next, or even after that? The bottom plates fell right off once the bolts were removed. Is that normal, or are these likely 26 year old ball joints that are completely trashed?
Thanks,
Michael

Answer
Hi Michael,
That ball can be a tough one because of the mild angle on the tapered shaft. Some mechanics are worried that a front suspension part can come apart so they tend to over tighten nuts. And on that part it pulls that tapered shaft in too tight. It is very difficult to get a good swing with a hammer on the end too. I have had some that were very hard to get out and some times I had to use several things to help. I have a large fork that I drive in and even though it don't pop loose I leave it in so as to keep a strain on the ball. Then I use an air hammer with a flat end on the threaded stud with the nut off because it will mushroom the end and if the nut was left on you would not be able to get the nut off. I alternate driving the fork in harder and air hammering the end and even on the side of the lower part of the spindle that has the pin trapped. (like loosening a tie rod end)

The trouble with using a hammer on the end of the ball is that the spindle assembly does not have enough mass and thus all the strike force is lost.

If you have the complete lower ball and upper and lower plate new you can try this too. Get a thick wall piece of pipe that will allow the ball to fit inside and place something like an anvil or heavy steel plates or steel blocks under the pipe to support the lower end of the spindle assembly and then use your large hammer on the threaded end. The solid heavy mass will not give at all and thus your hammer strike will be much more effective. But I found that an air hammer can put more punch than you can with a heavy hammer. This usually destroys the upper plate but when you have one that is tough it is a small price to pay to get a job done.

Howard