2002 Excursion, 7.3 4wd
I have confirmed that the correct parts were ordered, delivered and installed. Dorman HD BJ86315XL
Torquing sequence and specs were correct. 35 lower, 70 upper, 150 lower.
After multiple attempts and two different sets of lowers - still same problem.

Once the lower is torqued to 150 ft lbs it takes a ton of force with two hands to turn the knuckles.

You cannot make the lowers swivel at all by hand (like out of the box - prior to install)
Tried to loosen with BFH to no avail.

I am trying Moog today.

Question is (besides any clue?) can you "over press" a ball joint?
They loosened up considerable when I was pushing them back out.
I've never had this issue so feel like its the parts lol.

TIA

 

Ok, so turns out it was the lower ball joint on one side and the other side, the lower wouldn't seat properly because I had the camber shim in the top.

I took it out, set the lower to 40, put it in, set the top to 70, then the lower to 150.

Now you can easily turn either side.