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This is where it becomes counter intuitive. I need to ream the lower ball joint hole a bit deeper to clear the CV axle above. Probably the thickness of a thick washer. Go too deep and I need washers under the castle nut so the cotter pin goes through the nut.

I had over reamed the depth on the passenger side knuckle and it ended up “egged out” due to the looseness. I’ve already done the tie rod ream on the passenger side knuckle. Set the depth with with the castle nut snugged down to where the cotter pin just fits through.

Are those Mevotech ball joints? I was doing the same job (upper ball joints) yesterday: Today I ream the knuckles to fit tie rods and ball joint and it goes back together. Already reamed the passenger side knuckle for tie rod. This time set the depth so I could just get the cotter pin...

You have the OEM original riveted on upper ball joint.

I flipped the bolts the other direction, so the nut is facing the CV axle flange.

Reworked LCAs installed. So officially going back together and all the heavy work is done. Need to ream the knuckles for tie rods and ball joints.

I ordered a new Mevotech Sway Bar assembly from PartsGeek.com

By the presence of rust on that break edge, it must have been cracked from fatigue for awhile:

Dinner is not until 6:00 pm at my brother’s place in Corona Del Mar. I can’t really stuff myself with food anymore.

Found some additional damage. In the process of breaking the tie rod, it also broke the sway bar. Should I buy new or harvest one from a boneyard?

Success, both LCAs are off. I can now start putting this back together.

I call this the “Hillary Step” of Lower Control Arm removal. Driver’s side rear bolt is impeded by the CV axle flange on the front differential. Passenger side is not. Have to undo, lower and pry the diff over to the passenger side to clear that rear bolt. It is like a limbo dance.

I’ve recently ordered Raybestos slotted front brake rotors from PartsGeek.com. Their price was about half what RockAuto.com was asking and their shipping cost was far less. Order came timely. No issues. Ready to order more.

Go to PartsGeek.com as they are way cheaper on rotors. The Raybestos Advanced Technology Rotors are the same as the top end AC Delco. Screen captures of slotted and regular Raybestos for GMT-400 front: RockAuto will gouge you for shipping cost on rotors...

It was due to fatigue. I overdid the ream in the knuckle for the GMT-800 brake conversion and ended up with looseness there which caused wheel wobble and vibration at highway speed and obviously metal fatigue in the tie rod. Second half of this video shows the play in the tie rod that I was...

Made some progress today. Just need to remove the LCAs. I have a pair of forged LCAs already prepped with Energy Suspension bushings and Moog ball joints. Install those and then ream the replacement knuckles and I’m putting it back together.

I guess there’s always a first.

I said the same. I was lucky.

Well I did. I backed up there to clear the lane in the parking lot. It worked. Suddenly this job jumped to the front of the line in front of upper and lower control arms on my wife’s 2014 4Runner. Can’t do any work in the yard as it’s too muddy from all the rain.