This is where I bought my parts- SUSPENSION KIT PITMAN IDLER TIE CHEVY K1500 4WD 1994 on eBay.ca (item 330443147970 end time 12-Oct-10 13:34:03 EDT)
Had a **** of a time removing the upper ball joints because the previous owner believed that welding them on was the best choice....
cut off wheel and a BFH
working for chevrolet, I did a lot of these, the secret, is to cut the heads off with the air chisel, or just a hammer and chisel, they cut pretty easy.. then, before takign a punch to them, take a drill, and drill down into the center of the rivet, leaving plenty of shoulder for your punch.. the hole you drill down into the rivet, allows the rivet to collaps INWARD rather than mashing itself against the walls of the a arm, and they pound out MUCH easier... You do not need to drill all the way through, just far enough so that when you drive the rivet down, the expansion has a place to go rather than OUT... the rivets are soft steel, they cut easy, and drill easy, but they also smash easy when your pounding on them... once you have them all driven out, yes, you bolt the replacements in. You can do it in your garage easy enough. an air chisel with a punch the right size for the rivets that fit the air hammer are a major boon, no torch required.
The stock ball joints were riveted. Just take a drill and drill the center of the rivet then cut the head of it off with a grinder, new ones will bolt right in through the same holes.
Uppers on my 95 were riveted on...I used a grinder on the heads then beat them out. The replacement ball joints will come with bolts. It was kind of a pain until I stopped being shy with the grinder. The first side took 2 hours, second side...15 minutes
Just got done doing the upper and lower ball joints on a 96 k1500 4x4. Everything was simple until the last rivet of the upper ball joint. That thing would not come out for anything. I think I may have ground a little too much and welded the tops of the rivets to the control arm. Dremel cut off wheel and hammer made easy work of the others. Good luck. On the install, lower ball joint was a pain to push in straight. Other than that, straightforward.