Over the years I've done many CV halfshaft changes, and I have never had much trouble getting the castle nut off the ball joint of the lower control arm (right side). But this time there was a lot of rust, and the castle nut and stud of the ball joint were spinning freely. I tried PB Blaster, etc. but I had to cut it off at the nut under the lower control arm with a hack saw. The other side (left/driver) came off, but the pop trick didn't work. I had to use a puller... it built up so much force I had to grease the puller and when it finally popped loose it was sudden and the puller went flying, lol.

So now there is about a hacksaw blade's thickness of metal gone from the lower control arm. Do you think it is fine to replace the ball joint then use it as is, or because it is slightly thinner now, do you think I need to install a washer as a shim?

Or does all that get adjusted out when an alignment job is done?

Thanks..