While putting in lower ball joints noticed it did not take much to press them in. After I returned the ball joint installation tool and putting in the bushings the ball joint has popped out. Am I going to have to resize the sockets for them to fit tighter. Or get new A arms hoping there's a fix. Has this happened to anyone else?

 

You can't "resize" the ball joint hole in the lower A-Arms to my knowledge. There used to be, and may still be, slightly oversized ball joints available for situations such as yours....excessive receiver hole size in the lower A-Arm. That may be one option...if these oversize ball joints still exist.

I've seen lower A-Arms where a ball joint was apparently replaced and must have fit "loose" since there were a couple tack welds where the ball joint rested in the A-Arm hole. Never thought that was a great idea.

 

Check Moog K5103 supposedly oversize and with serrated edges?

 

This is what I put in. K5103

 

If the oversize ball joint fits too loose unfortunately your gonna have to replace the arm. Either that or (carefully) weld it in. There used to be double oversize joints but I don't think they're made anymore.

 

Mine are tac welded. I didn't know there were oversize ones available. It was pretty common back years ago to tac weld them in. My alignment came out fine.

 

Thanks guys looks like I'll have to tack weld them in. Sounds like tack welding was a normal fix back in the day. All I have to do is put the welds in the right place so that if I have to replace them its not to bad the cut the tacks off.
At least I don't have to buy new A arms.

 

I would not worry about the next time. The net time they should be replaced.

 

As mentioned the two options of tacking the joint in place or replacing the arm both sound good.

Here is an idea, remove the ball joint, line the hole in the arm with overlapping shim stock for example .010" to create an interference fit, press the joint back in and trim away the excess shim stock??? Thoughts/comments anyone?

 

Ok I'll keep the wire in my welder cold until we here of this idea.
Only thing, for as tight of a fit I have .010 my be to much. Of course I could go .005 but keeping it in the area needed during the press is the challenge. Its hard enough with my wife and I doing it with the required parts.

 

Overlapping the shim stock so that it extends out on the side of the arm/hole that joint enters from may help keep it in place. Keep us posted...

 

I think it will just sheer the shim stock, I would just weld them and be done with it. You probably won't have to replace them again in your lifetime.