Hi axleman, I can see your frustration with the rest of the comments on this post. It's like asking how to make an omlete and getting replies saying "I don't know how to make an omlete, but I can help you make a cup of coffee, but be really careful when you boil the kettle in case you burn yourself".
Most of the replies on here seem amateurish at best.
You are correct in your assumption, the outer CV joint casing gets in the way, preventing you from removing the balljoint from the steering knuckle. I know that you will have fixed it by now, but I will post this for the benefit of anyone that is searching for a solution to this problem.
There is a knack to doing this - You will need to remove the circlip from the driveshaft (by removing the free-wheeling hub body and clutch assembly from the hub body and you will see it - you don't need to touch the wheel bearing adjustment). This will enable you to slide the driveshaft out of the way by a couple on inches and give you the necessary clearance to remove the lower balljoint.
Why don't people read the question, and then if they know the answer and ONLY if they know the answer give a reply.
Most of the replies aren't even related to your specific question - Why do they reply if they don't actually know. They just make themselves look stupid!
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