1st Gen Icon Upper Ball Joint replacement Issues

I always like wrenching around on weekends and this weekend I was particularly excited to Install my new Icon UCAs (58400) and Coil-Overs (58615) on my 04 TRD extra cab.

Getting all the old stuff off went pretty easy. The UCA went on pretty easy, though I had a few issues while trying to seat the Upper Ball Joint replacement part. Maybe because I was trying to do everything with out removing the spindle?

Problem #1 - The Ball Joint Press didn't fit in the fender well very good...


Problem #2 - The BJP fit good enough with a flat piece of steal I was able to get it seated far enough I thought I'd try to use the bolt to bring it in the last 1/8"...


Problem #3 or 2.5 - arg... So Threading in the bolt, was easy (so I know it wasn't cross threaded) but the last 1/8" (plus the 1/8" need to complete the seat) it got a little sticky. Figure it just needed a little elbow grease... threads are done! I know by looking at it, you'd say I started with the threads crossed but going the 1st 3/8" was finger loose.


So where do I go from here?

Obviously I need to repair the thread or get a new part. But these are what I think my options are.

1- Turn about 0.002" - 0.004" off the part that mates with spindle. To make it easier to install?

2- Remove the spindle and find a real press to seat the part?

 

If your trying to get a puck thing into your spindle I found that freezing the puck before hand and putting a propane torch to the spindle I was able to put the puck in with my hand and two small taps with a 16oz hammer.

 

I did use a torch on the spindle, but I didn't try putting the puck in the freezer

 

Freezer will make the difference. Just make sure it stays in there for an hour or two, could wrap it with a wet paper towel to get it colder faster. Then right when/before you take it out torch the spindle for a good minute or two.

 

What kind of press did you use? Cause mine isn't fitting in there very well.

 

I didn't use a press. I just did what I said, I froze the puck and torched the spindle and then my TC puck went in super easy with just two light taps of a standard hammer. The other puck I beat in with the hammer + chisel/long handle screw driver and c clamps.

 

Dude! I use the torch all the time to help parts fit... But I never thought the freezer could help out so much! Combined it fell right in! Like a hot dog in a hallway! Though I decided not to take any chances and removed the spindle from the wheel well so I'd have room to use the press correctly if I need it.

Thanks for the advice!

Now I just need to see if I should replace the fucked up part or try and fix it... guess it depends on how much one cost.

 

Haha, so I actually got the opportunity to help presto with his install, and yeah, that was pretty much our reaction too! I think we spent like several hours on the first side. Read about the freezer trick somewhere, so we popped that suckered in, got some lunch then came back... voila, took like 10 mins to finish the other side.

Good luck with the other part, that's pretty weird. Maybe the threads were gunked up and it caused damage?