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Hi Griff, not quite sure how you got a 19mm forked ball joint seperator into the bottom ball joint? You need at least 24mm opening

Yes, I have been hitting the steering knuckle right at the ball joint taper. The knuckle has to move downwards off the ball joint tapers once they are freed, so hitting the knuckle arm downwards as well is correct?

Thanks Griff. I have ordered the E Bay version and will give it a go.

I am replacing the steering knuckle ball joints on my S2D and have a suitable ball joint removal kit (Chinese) from E bay. However I need to remove the ball joint from the steering knuckle to remove it and gain access to the ball joints to remove them from the casing first. The usual two...

I have 4lb clump hammer, it is seriously marking the steering knuckle. The top one popped easily, but the bottom one is resisting all attempts. I think a splitter with pressure on then further banging is called for. :o)

This might be the complete address for the Puller kit...

Thanks the Mad Hat Man, yep I have a https://www.ebay.co.uk/itm/10pc-Bal...m=263826408602&_trksid=p2047675.c100005.m1851 waiting in the wings to push the damn ball joints out of the axle casting. What I cannot get off is the steering knuckle, the lower ball joint is still resisting all...

OK well you cannot cut the lower ball joint off, the steering knuckle is shaped such as you cannot get a blade or disc cutter all the way through. So that's that idea stuffed. So looks like I will have to invest in the proper puller (more expense). Any recommendations for a puller that stands a...

OK Mate, Viscous Fan spanners on their way. Havent even seen the back bolt for the alternator yet! I will report back when I have the damn thing off and on the bench, so dont hold your breath.:o)

Well this is well stuck. I have heated the knuckle and belted the living daylights out of the ball joint, but the taper joint won't break. Maybe I will have to cut it off and remove the knuckle to the vice to belt it out. However I am worried about having enough of the remaining ball joint to...

I am pleased to report progress. The hub parted company with the steering knuckle with the judicious use of a reasonably sharp cold chisel. Both ball joint nuts have been removed and the top ball joint freed with the use of a large clump hammer. The bottom ball joint is so far resisting all...

I'm in Malmesbury Wilts. Yep, you are right the hub is well rusted on and impossible to move. Cant undo the hub nut either. It is normal anticlockwise and not a left hand thread?

I am at the point where the four bolts connecting the hub to the steering knuckle are removed, the ABS cable disconnected and free, calliper and back plate off. Rave talks about removing the drive shaft nut, which looks a bitch as the nut is peened over into a recess. Can this be left on and...

Thanks Sierrasafery. I think it would be a good idea to remove the alternator and have a look. Dont fancy paying £150 for a replacement alternator if its an O ring problem. However I have seen pictures of other O rings including seals around the fixing bolls too. Also shaft seals from Denzo and...

Thanks James. OK the PAS pipes at pump are dry, no problem there. I now understand purpose of vacuum pump (feeds brake vacuum chamber) and the oil feed I guess lubricates the internal vanes. The unit under the alternator is the pulley tensioner I think. So, I gave the oil pipe into the vacuum...

OK guys the plot thickens! With the area all cleaned up and the battery back in, I ran the D2 up and gave the steering a good old waggle. Underneath not a sign of PAS oil from either input or output shafts or any part of the PAS box, as dry as my front lawn. Just the smallest misting from the...

Thanks Meego. I now have the PAS box in view. As the loss was so slow: 1mm in the reservoir a month (don't do many miles) and there is a general coating of oil all around the box area, to clean it all up, reconnect the battery and run the car. That way I could confirm it's the PAS box and not...

Thanks for all the info guys, much appreciated. New steering rod on it's way. Very reasonably priced too from JDS 4x4

That sounds good Darren, with the limited mileage my old D2 does, this could be the route then.

Absolutely. My intention was a real good clean up, a few days of WD40 applications, wind initial tension on with the clamp, whack with large clump hammer, wind a bit more on and repeat. I know this will take time too.