Knurling may be a temporary cure. Best bet is to replace the spindle.
If you must remove a ball joint in the future, do not use a 'pickle fork'.
Instead hit the control arm hard with a bigger hammer on the side of where the ball joint stud passes through. This will break the taper fit and the ball joint bolt will easily slip away from the control arm in which it passes through.
Hope I helped you

-----gimpster-----

 

Gimpster - Is there a way to get the bearing seals out w/o destroying them? I think they are cheap, but I'll install these bearings in the new spindle myself if I can salvage the seals, that would be great...Also, how are the bearings held in? C clip under the seal on each side?

 

Not saying it is not possable to remove the seals without damage, have to be careful though. I use a seal puller. Snapring is under the seal on drum side of the spindle. Even with a good snap ring pliers I've had them launch across the room. Bearing should come out pretty easy if it as loose as you say. Be aware that on the axle side under the seal there is a lip of the spindle that is not part of the bearing. Don't try to drive it out by hitting on the outside edge of the bearing, you will be hitting the spindle's bearing stop (lip)
Sure wish I could see how loose it is to really help more
-----gimpster-----

 

Thanks. They are loose enough that when you put your fingers inside and move them around, you can see the outer race move slightly inside the spindle. Slight movement there turned out to be alot of axle/tire movement w/ the tire on. they are loose enough they should literally fall out...that's why I'm hoping Honda will remove them and install them in the new spindle no charge as they should have known that they were too loose to work. We'll see; if they won't, I'll do it myself. Thanks again.