Well after the first side as a learning experience dissasembly the second went quickly, took less than an hour. I am having one problem getting it all back together but I'll get to that. I originally tried to get the springs out without dissasembly everything, but there was no way that was going to work. I'm not sure if it's the heavy, longer springs of the 99+, a different control arm, or both; but there was no way I could get those springs out (and especially not back in with a 1.5" spacer) without taking everything off of the control arm. I even tried using a spring compressor, but it got in the way more than anything else.
Now what is the easy way to seperate the steering knuckle from the balljoint...
1. tap around the ball joint area with a hammer to loosen it up some.
2. center a jack underneath the pin of the ball joint, and raise it just enough so that the ball joint transfer's any force directly through the jack and into the ground.
3. take your favorite BFH (I used a 4lb sledge) and give the steering knuckle a few good whacks directly above the ball joint. This should be on the top of the strut mounting point of the steering knuckle.
4. slide the steering knuckle off easily after you take the jack down.
Now to my new problem. I have the passenger side all together, torqed to specs and everything. The driver's side is almost back together except.... I can't get my BDS strut extension onto the end of my strut. It is just so tight I can't even get the threads to start so I could apply some force to it. I could get another bolt (the other strut extension) screwed into it about half way, but then it get's to tight for me to continue. I'm thinking tomorrow I will get some more cutting oil, another bolt that I can use to test the threads all the way in, and possibly a tap and die to make sure both the extension and the strut have good clean threads. Does anyone know the size and pitch of the strut? I can't remember. Also I'm open to any alternative suggestions you might have on how to get the strut extension on.