Hi, I’m looking for some advice. I’ve just changed the wishbones on my fiesta and have come unstuck on the final bolt… 

The pinch bolts in the ball joints were a nightmare to get out and I ended up using a penetrating oil, hammer and a punch to shift them as seen on these forums. I fitted the new wishbones without too much grief and brought new pinch bolts from my local Ford dealership for the ball joints. The first one went in okay, but the passenger side one just won’t go in. I’ve tried grease, heating up the cast iron and using a hammer. I considered that the bolt may be a rouge one from the factory, so tried swapping it with the other side that went in fine, but same issue again with the other bolt.

I can’t see any obvious issues with the hole in the cast iron pinch part, it just seems like the hole isn’t quite big enough. The bolt goes in a third of the way and then just stops. I also tried putting the nut on and tightening to pull through, but again no.. 

I’ve given up today and will try again tomorrow, I’m thinking of using either a round file in the hole or a drill to try and make it a bit bigger. The bolt has a score mark on it so it’s clearly catching somewhere, but it’s difficult working out exactly where as I have to use a bit of force to knock it out again and the bolt comes flying out on the floor. 
 

Any tips would be much appreciated.

Hi There,

Can you remove ball joint away from clamping point (lower away ball joint on wishbone) then try bolt through both holes which should go in

fairly easy may need light tap with hammer, If ok great if not then look for any damage at inside edge of holes and clean up. Check then for any

damage on ball joint pin where the bolt slides along the side. If ok great if not clean up or maybe turn ball joint around causing no damage to

fresh slide spot, Using rag wrapped around ball joint top pin with grips. And lastly before assembly use cold chisel and hammer to open

split (just a few taps) to make sure ball joint goes all the way up. Make sure with eye that ball joint undercut ring is in line with outer holes

 Then insert pinch bolt hope that helps

It sounds like the joint just isn't lined up.  It might have pushed through slightly too far and need to be pulled back a little with a pry bar.  Or not pushed through enough and need a tap to seat it.

Don't just keep hammering it as the bolt will either bend or wreck the threads...been there, done that!