I installed the PST kit on my bird and noticed that the boot for the upper ball joint doesn't contact the spindle to make a tight seal to hold the grease. It may hold grease for a short while but dirt and grime are going to get in there.
I thought that my problem was that when I upgraded to disc brakes that the guy must have sold me the wrong setup at the swap meet and I was OOL. He said they were off of a 69 camaro and that they would fit. He had them on for about 6 miles and wanted the front dropped 2" so traded them out. It looks like 67-69 have same upper ball joint but now I'm scrathing my head like 24GO24 is.
Scott, I think that you are onto something about the stud being longer. Do they make a longer boot for the longer stud? this would fix the problem with our rides as long as it isn't changing geometry in some negative way. Or it could be that the stud is slightly larger in diameter causing it to sit higher in the spindle, but the nut seems to be correct. Either way something is wrong here.
I wonder if I got a new balljoint from the local supply house for reference if that might lend towards a solution.