The hole in the steering knuckle for the ball joint is out of round. What is the best method of repair?

Replacing the steering knuckle is the most effective method of repair when the hole for the ball joint is out of round. Steering knuckles are critical components that directly influence steering geometry and suspension alignment. An out-of-round hole can lead to improper ball joint seating, which can cause premature wear, looseness, and potentially dangerous steering behavior.

By replacing the steering knuckle, you ensure that the new component has the correct tolerances and integrity to maintain proper vehicle handling and safety. This approach also eliminates the risks associated with attempting repairs or adjustments that might not restore necessary alignment or strength.

While measuring the wear can provide useful information about the extent of damage, it does not resolve the fundamental issue of the compromised steering knuckle. Reaming the hole might seem like a potential fix, but it can lead to an improper fit or weak connection for the ball joint, thus compromising its performance. Similarly, shimming the hole might temporarily mitigate the issue, but it would not provide a reliable long-term solution and could lead to further alignment problems.