Upper A-arm ball joint problem

[Jon Pike <jhpike@xxxxxxx>]

I had the frustrating experience of tightening the ball joint nuts on my 
new adjustable upper A arms tonight,  only to have one self destruct 
it's threads..   Yes, despite my budding reputation as a serious 
overtorquer... (I really DON'T resemble Arrrrrnold, really!!)  I used a 
proper torque this time (listed at 54.2-61,  I set for 58 lb ft) the 
threads weren't greased..  I don't know what happened.

The lower arms tightened nicely at the same torque,  they didn't have a 
castelated nut.  The top's had castle nuts.  The first top felt a little 
soft,  or took a while to tighten, but finally did.  The second just 
never got tight, then shavings started coming out.   I now can't even 
remove it.. it loosened part way, and I guess it finished the job of 
eating the threads.

So, why might this have happened?  Bad nut?  Un-chamfored cotter pin 
hole in the shaft?  "FRAP is crap"??

More importantly..  (besides my conversation to be tomorrow with where I 
bought these) what's the best way to get this thing off again,  besides 
cutting a hardened nut with a grinder?

And,  has anyone had similar problems.. and with which kind of 
adjustable A arm assembly?  I'm a little leary of trusting the other 
one..  but should I try to get a different brand altogether?  Is FRAP 
normally this bad or is this an unusual occurance?

Bad thing to happen when I'm trying to get back on the road in a week or 
so..

Jon and Marcia
77 Spider
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