In Reply to: Ball Joint removal....There must be a better way. posted by Paul Gill on December 21, 1999 at 11:21:09:
I don't even use a balljoint separator or air hammer with separator. I fine they don't work very well. What I use is a 4 lbs. mallet and a very big screwdriver or chisel. Sometimes two mallets on old chevys. On a Bimmer loosen the nut on the balljoint so that the top of the nut is even with the end of the threads. Wedge the big screwdriver or chisel between the balljoint nut and the buttom of the strut or knuckle. Knocking it in with the mallet so its good and tight putting pressure on the balljoint. I then hit the side of the knuckle that the balljoint is pressed into the pressure and vibration will cause it to loosen. You may have to wack on the screwdriver and balljoint a few times but it will come loose. On old Chevys that don't have a strut in the way I use two mallets hitting the top of the balljoint/nut at the same time I'm hitting the knuckle with another mallet after three or four well timed blows it comes loose. If it doesn't appear to be loose check by hand. On my 735I the tension from the bushing kept the joint in the knuckle It looked like it wasn't loose but when I grab it I found that it did come loose from the knuckle.
Let me know if this works for you.