Hi Keith, photo helps a lot.
Are you having problems with the stud of the balljoint engaging into the control arm, or the main body of the swivel hub?
If it's hard to get into the hub, I would remove it, look to see if you've created any burrs in the counterbore, clean them up (also take sharp edges off the balljoint housing) and reinstall. I bet if this is the problem, the balljoint is cocked slightly in the bore. I think I would use some sort of jack to press the balljoint in, start the bolts into the hub, get them snug,, attach lower control arm to the balljoint, snug that down tight then apply upward pressure with the jack on the lower control arm to drive it up. The weight of the body of the car and the spring pressing downwards should be enough to see it into it's bore.I would use alarge socket over the balljoint spindle and nut so you apply pressure to the control arm around the balljoint stud, rather than through the stud.
The reason I suggest reassembling control arm onto balljoint before doing this is to the whole assembly is back together and you are applying upward force safely (for both you and the parts). I also think that as you jack the control arm/hub up, the angle on the joint will become much more in line and help set it all up for you. As you jack it up, try tightening the bolts a little as well, use the jack AND teh bolts to apply pressure in the direction you want to go. Remember, a thread is just a round wedge!
But also remember you are tightening into aluminium, so not TOO much pressure.
You could also apply some heat to the bottom of the swivel hub around the balljoint housing, the hub is aluminium, so will expand readily with some heat, and also being aluminium, will expand at a much faster rate than the steel/iron balljoint.
Last edited by Typhoon; 11-11-2009 at 04:40 AM.