I recently replaced all driver side components struts,springs balljoints etc., when installing the knuckle the NEW upper ball joint stud fit fine but when putting the crown nut on it went past the hole so that the cotter pin would be useless, I put a couple flat washers to take up the room and proceeded to put the car back together, now I am having second thoughts was the ball joint incorrect? or was the knuckle worn? The original upper joint wasn't loose at all I had to slam it out with pickle fork and pressure from a tie rod end remover. Any input would be appreciated. I havn't done the other side yet.

 

dont worry about the cotter pin they dont really actually hold it from loosening i know the ones in my accord are the same way but ive never had a problem with it

 

It should be OK the way you assembled it too (unless you used plastic washers).