It almost sounds as if the spindle nut is on beyond the torque settings or that the bearings are not getting packed fully. Either way, too much heat and we got unhappy bearings. I am not sure about the ball joints affecting, although if they are way loos, then the whole knuckle drifts, putting pressure on the bearings, which could cause heat issues.
I would check that your bearings are getting properly packed, and that when you replace the bearings, you get the races replaced too.
Might be a good idea to make sure you are packing with the right type of grease too. When I did my front end, I used bearing grease that was in a grease gun tube, and then pumped it through my cone packer (picked up at Pep Boys for like $6)