Ball joint is a rotating and swiveling element that is typically installed at the interface between two parts. In an automobile, the ball joint is the component that connects the control arms to the steering knuckle. The ball joint can also be installed in linkage systems for motion control applications. This paper describes the simulation strategy for a ball joint analysis, considering manufacturing process. Its manufacturing process can be divided into plugging and spinning. Then, the interested responses is selected as the stress distribution generated between its ball and bearing. In this paper, a commercial code of NX DAFUL using an implicit integration method is introduced to calculate the response. In addition, the gap analysis is performed to investigate the fitness, focusing on the response of the displacement of a ball stud. Also, the optimum design is suggested through case studies.