Help on W201 1989 190D Can't get tie rod into steering knuckle the last 1mm?

[bruce.g.cameron]

So I've gotten most of the way through replacing ball joints and control arm bushings, but have gotten stymied at the last step.

I can't get the ball joint up the last 1mm into the steering knuckle hole, so that I can comfortably insert the bolt to tighten the ball joint on. The issue is that the groove that is carved into the ball joint is just wide enough - if the ball joint shaft isn't all the way up, the full cross section of the ball joint shaft is visible in the bolt through hole. I've already busted the threads on one bolt trying to pull the bolt through (and the ball joint shaft up!)

I've tried jacking the control arm up, but only against the force of the strut, not with the spring in play.

I also tried cleaning up the top of the hole the ball joint shaft fits into - it looks like plastic + rust at the top. When I remove the ball joint, there are some beginning signs of wear on the top, as if the top of the hole is interfering with the shaft going up all the way.

I also tried sticking a screwdriver into the gap (intended to help you remove a frozen ball joint shaft), but I don't think it had much effect.

The only thing left I can think of doing is :

- take the tension off the spring compressor (right now the spring is compressed for safety)
- jack the wheel up right under the control arm

In theory this would place more 'weight' on the ball joint, but at the risk of having the spring pop out if the ball joint fails downwards.

Your thoughts would be greatly appreciated - I'm looking forward to getting the old girl back on the road!

Bruce

1989 190D 60k miles.