Popping / knocking noise (ball joints / tie-rod ends?)

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Make sure a needle bearing didn't dislodge and fall to the bottom of the cup. That keeps the cup from seating fully against the cross

That’s exactly what I was thinking happened so I took the joint out and the needles are everywhere. Going to see if I can’t exchange it, if not I’ll buy a new one.

I also found out that I require knurled ball joints. Have to return the spicer ones and get knurled now. Nothing is ever easy. Time for whiskey 🥃
 
That’s exactly what I was thinking happened so I took the joint out and the needles are everywhere. Going to see if I can’t exchange it, if not I’ll buy a new one.

I also found out that I require knurled ball joints. Have to return the spicer ones and get knurled now. Nothing is ever easy. Time for whiskey 🥃

Dimple the spicer balljoints with a pointed punch all over to make up the space.
 
Well I’m officially stumped. It just doesn’t make any sense.

Replaced:
front u joints
Upper/lower ball joints
Shocks
Upper/lower control arms front/rear
All tie rod ends
Sway bar links
Track bar
Pitman arm
Upper/lower steering shaft
Steering gearbox.