2006 Double Cab - upper ball joint insert pulled free of spindle

Just posting for some thoughts on a weird occurrence. I have a 2006 double cab with SPC UCAs and upper ball joints (stock steering knuckles). Yesterday the dog distracted me (problem I know) as I turned into a parking lot I drove over the corner of a curb, direct on at very low speed with the passenger side. I mean it wasn't ideal but it was by no means a violent event - I've had worse of forest roads.

I immediately knew there was a problem. At first it seemed the upper ball joint on the driver's side failed. Further investigation (after a tow home) revealed the ball joint was fine. The insert ring that goes in the hole I'm the spindle (steering knuckle) had simply lifted out of the spindle. It inserts from the top and is retained by a c-clip below (missing now obviously).

I see no other damage on either side. Lower ball joints seem tight (replaced under recall) when checked with a pry bar. It's so odd to me the problem was on the driver's when I hit the curb with the passenger side and nothing seems wrong with the passenger side at all. I throughly checked it all.

Is this simply a freak occurrence in that I may have lost the c-clip retaining ring at a previous date, and driving over a curb with the passenger side caused it to cant at just the right angle so the dang insert and ball joint lifted right out ad one?

I have new ball joints on order, and also new "upgraded" inserts from SPC that insert from the bottom and are retained with the ball joint castle nut on bottom and a c-clip on top vs the previous design that was held by a lip on top and c-clip on bottom. This design seems to be better at preventing this, also they are designed to expand in the spindle hole as you tighten the ball joint castle nut.

Do I just replace both sides with new inserts and upper ball joints, get it aligned and double checked, and chalk it up to a freak event?

I've heard of lots of ball joints breaking, but never the insert simply lifting out of the spindle. Any stories/theories/advice are appreciated. I just am a bit shook because I go very remote and rough places and ball joints are kinda critical.

Sorry for crappy pics. Thanks all.

 

Looks like you have the old style knuckle adapter, or puck. The newer style goes in "upside down" with the clip on top of the knuckle.

I would try that.

 

So playing devil's advocate for a sec.

Local Toyo/Lex-centric shop that focuses on offroad/overland builds tried to steer me towards going full-Icon for everything. When I asked "why not SPC on the uppers?", they specifically warned me about he issue you're seeing, and/or risk of the clocked SPC UBJ bouncing to a new clock position. They mentioned this was the one uneasy fail point of this setup, they "preferred" using another brand, and love Icon's upper with delta joint upgrade.

Needless to say, I've never heard of or seen it happen with properly installed arms. I didn't want to spend $1k+ on arms and joint upgrade, and I didn't want a standard uniball either. So I went with SPC.

However, it is possible to install that adapter upside down, and it happens. Noah ^^ actually did this and had to order new ones

 

I think that's how the "old style" (non-slotted) SPC inserts are supposed to go in - from the top. I hope. I had a local expo shop put them on in 2016. Wait...are they supposed to insert from below as well??? Gotta download instructions...

The upgraded expanding inserts (install from the bottom) look like they may help prevent this.

I dunno it just weirds me out. You always hear of LBJ failure but I've never heard of this happening.

Hopefully I was just unknowingly driving with no retaining ring on the insert and this bump hit just right to allow it to pop out.

Not a great feeling seeing this fully packed 8 million ton DC flounder with the ball joint hanging loose in the air.

Edit: other concern is I have stock spindles and the new inserts mainly mention aftermarket. I guess I'll just have to see of they fit when they arrive.

 

I can Confirm, recently I installed some SPC’a on the Sequoia, and they insert from the bottom.

But still, I’m wondering if the snap ring wasn’t fully seated.

 

Like @shifty` said, I had mine in correctly the first time, but I saw another install sheet online for a 4Runner, so I flipped one side over. Only to realize that I was stretching my steering knuckle, and the adapter/puck/slug. My arms came with the newer slug though.

Here's a link to what @shifty` was talking about. https://www.tundras.com/threads/crackhead-resurrection.94083/page-64#post-2874010

 

I went around the outside of the snap ring with a hammer, and punch to fully seat it in the groove.