I had a replacement pop out once. Good thing I was turning around in the driveway.

a few tack welds held the ball joint in place for nearly 3 years…

 

Do you have a theory on why it was loose enough to pop out?

a) Undersized replacement ball joint?
b) Ball joint not pressed in straight, enlarging the hole?
c) Flimsy/soft control arm material such that it deformed when bj pressed in/out
d) ____________

 

Control arms deform/stretch when bjs are pressed in/out. it's just stamped steel after all.

 

Yeah, it'll probably a good idea for me to hit it with some penetrating fluid a day before and then try to get some lubricant on there before pressing it off and on

 

Yup, my thoughts exactly.

Its too bad that a simple ball joint job has potential to end up in an control arm removal/replacement.

FWIW, I spent the money on a good ball joint set and it has served me well over the years. it was able to pop both ball joints out without any lubrication or perpetration work (besides removing the knuckle).

I suppose a loaner tool from auto zone is also a good way to source a kit…