I replaced an upper ball joint yesterday. The NAPA Premium joint instructions calls for 65 lb ft torque, but the 72 Service Manual calls for 40 MINIMUM. That is a large difference. Is there something about the replacement that would require more torque? I know not to loosen to insert the cotter pin. Does 40 minimum mean 40, 50 60, who cares, doesn't really matter, or should it be pretty close to 40?

 

I've always used around 50 for the upper and 80 on the lower. To get the cotter pin in, always tighten to line up the castle nut with hole, never loosen.

 

I followed the CSM. It also says to never back off the castle nut to put in the cotter pin. When you get to 40, you may have to go beyond to get the hole to line up with the castle nut. That's my take on it.

 

I did 50 also. Sometimes aftermarket parts have different requirements than the originals. I replaced my Combination valve on the factory disk/drum brakes, and the instructions said DO NOT depress the pin to bleed the brakes unless it is off center and no fluid will flow.

 

This is how I see it also. At 40 you may just pass the hole. It might be 50 or so until you can get it there again.
Keep in mind some parts may have two holes for cotter pins. I had one like this but did not know it on the first joint. Instead of making another half turn, i could have had done just a quarter.

 

HALF turn?
WTH kind of castle nut were you using?
Generally they have slots every 1/6 turn, so if the stud has two holes, figure at most 1/12 more turn to get something to align.