I'm sorry to say that a HHR SS lower ball joint has still not been sourced as a separate item, only available as a complete unit.

 

I talked to the catalog manager at MOOG, he said that they do not list a ball joint for the SS. He was unaware of any data book for cross referencing ball joints.

In the same conversation he agreed to correct the part number for the sway bar links, I have not checked, but he said it was done for the November catalog.

At least, they don't list the incorrect parts!

If you are adventurous you could go to an auto parts place armed with a micrometer and a ruler then get them to pull several parts for you for similar vehicles. Then tell us the results.

 

I've read thru this and thought of a possible solution.
From what I understand the wrong ball joint has a diameter of 20 mm and the correct one is 20.5 mm.
.5 mm converts into .020"
20 mm is about equal to 13/16"
The ideal situation is to finding tubing that has an ID of 13/16" with a wall thickness of .010"
Making a sleeve to go over the "bad" ball joint stud is a no brainier and then cut a slot in it to accept the pinch bolt.
The problem I've been trying for find is the tubing for this.
You can use .010" shim stock and roll it, but looking for an easier solution for people that don't have the tools or the skills.
You could use steel, brass or aluminium for this. Once that metal is captured, nothing is going to move/wear.

 

I wonder if this is one of those things that already exists, just nobody knows about it? Seems like sleeves should be commonplace in machine shops. Of course you could just go to Canada and get a 20mm id X 20.5mm od, cut it, slide one part below the groove one part above. Probably make a good enough force fit.

 

How about a .010 in. feeler gauge or .25mm cut to fit, and formed around the stub? Or would that be too thick to work with?

 

The problem with the sleeve idea is the pinch bolt wouldn’t catch in the groove in the stud enough for my safety specs, I deem it an unsafe practice, I mean you could do it but I wouldn’t.

 

That's why I said to cut it and place a piece above and below. The bolt serves to hold the stud vertically, the pinch keeps it centered.

 

You could place the sleeve over the stud, place the spindle on and use a drill bit in the hole for the pinch bolt.
Or take a die grinder with the sleeve on and notch the area of the pinch bolt groove on the ball joint stud.

 

So, when do you guys call it "under-engineered"? If it was a good design, it would have proliferated, right?

This was a huge disappointment to me as my unstable alignments munched front tires.

 

It amazes me that somebody that calls himself a "front end specialist" would let that off the rack!