I've got new tie rod ends, but the holes in the bolts don't match the castle nut slots; the hole is actually a few mm below the very top of the castle nut. So the cotter pin isn't through any of the gaps. Right now it's bent up to hit a gap, but that doesn't seem like a good long term solution.

I don't wanna drill a new hole; it would be too close to the old one.

I've seen some installations where folks use nylon lock nuts. Or the all-metal toplocks with the deforming threads. Should I use those?

Or what about putting a nyloc on and backing it up to the castle nut? The castle nut is properly torqued, so the nyloc would just have to contact it. Can't imagine it could generate enough force to back both down.

I guess I could also stack a couple of thick washers, but somehow I think that wouldn't be much better.

Rob

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2001 Ford E250 Sportsmobile with Salem-Kroger 4x4 conversion

Here's my thread with a few pictures. Maybe it will help.

viewtopic.php?f=3&t=2230&hilit=+rod


Herb

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SMB-less as of 02/04/2012. Our savings account is richer, but our adventures are poorer.

Get the parts from Quigley directly using your VIN, and save yourself a big hassle at Ford.

Are you sure you got the right tie rod ends... doesn't sound like it.

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Four time Baja 1000 winner, four time Baja 500 winner. Solo'ed the Baja 1000 to LaPaz/Cabo twice.
4-Wheeling since 1972, Desert Racing since 1989.

AgileOffRoad.com

When installing drilled shank fasteners and castle nuts on aircraft, it's totally cool to stack a 2-3 washers to get the nut to the right height. If you need to stack more than that, it's time to get a shorter bolt.

Of course the right length fastener is always preferred...

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2006 E350 Diesel, SMB 4x4, RB50- "Hopper"- SOLD

The question is not the length it is the taper and diameter that could be wrong.

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Four time Baja 1000 winner, four time Baja 500 winner. Solo'ed the Baja 1000 to LaPaz/Cabo twice.
4-Wheeling since 1972, Desert Racing since 1989.

AgileOffRoad.com

Everything is correct. It's a very long story, but the parts are all we could get to fit this Salem Kroger build. It's all fine, it's just that the hole is a bit too far from the notches of the castle nut.

Some folks have told me not to use a washer, at least above the castle nut. Others do it all the time.

Something I hadn't thought of until it was suggested was just to back another castle nut up against it and secure it with the cotter pin. Duh, that might work. And having had some major battles with badly corroded castle nuts and broken off cotter pins, that might even be a good idea.

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2001 Ford E250 Sportsmobile with Salem-Kroger 4x4 conversion

Just use washers.

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Four time Baja 1000 winner, four time Baja 500 winner. Solo'ed the Baja 1000 to LaPaz/Cabo twice.
4-Wheeling since 1972, Desert Racing since 1989.

AgileOffRoad.com

And after banging around seeing if they wouldn't produce any unforeseen problems, that's what we did. The washers. Seems to be working fine.

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2001 Ford E250 Sportsmobile with Salem-Kroger 4x4 conversion