91 Taurus front ball joint problem

So, the sister-in-law's Taurus needed a shopping cart full of stuff for the front suspension before it would pass inspection. I got everything off OK, and got ALMOST everything back on. I cannot for the life of me get the control arm ball joint to seat in the knuckle. If I didn't know better, I'd say either the new control arm or the halfshaft was 3/4th of an inch too long. Of course, they're not, but no matter how I much I wiggle it all around I just can't get the hub to move back that 1/2 inch or so.

I figure I must be missing something stupid, but if there are any little tricks you all know of, let me have em. I'm tired of fighting with the car!

Thanks

I'd suspect that the inner CV joint popped apart inside the boot. Take a look at the CV joint rubber bellows and see if all the ridges are continuous ridges around the diameter. If one or two near the transmission side are lobed, your joint popped out. You will probably need to put the transmission in neutral and try to get the halfshaft as straight as possible, then rotate the hub while gently applying inward force on the knuckle. After a revolution or two, the joint should pop back in place and you'll get the 1/2 inch or so that you need.

-Rod