I changed all of my tie rods this weekend . and when I went to torque them down to 67 ft. lbs. as per specifications. I found out that the castle nuts went on to far for the cotter keys to even touch the nut let alone go inside the slots. It is like the studs were to long. So when I compared old ones with the new ones they were almost a 1/2" longer. this was on the outter ( both left and right ) tie rod ends. of my ( 2000 EX 4x4 7.3 ). Oriley's said they were the right parts. every thing else looked good and fit good except for the castle nuts. SO NOW WHAT DO I DO.

 

If you're sure all else is the same (rubber bushing seated height, extra stud height can't hit or rub any other components, etc.) then just drill a hole for the cotter pin, as long as you're positively satisfied all else is correct!

 

Or you could stack some flat washers until the slots in the nut reach the cotterpin hole.

 

Same prob on my '03 when I put Moog ball joints in place of original--the cotter keys did not intersect the slots on castle nuts.

I did not do anything other than to put the cotter keys in the hold anyway. If the nut ever comes loose (it has not now for over 15 months), then I assume cotter key will "catch" the nut.

By the way, I doubt if you could drill this small hole in the ball joint stud. Too difficult--especially now that ball joints are on the truck.

 

Go to another parts store that sells a different brand and ask to see one. Compare, contrast. Maybe return teh ones to oreilly? Id at least look at one more set, and use those if tehy matched what was on my truck. I wouldnt feel safe rilling anotehr hole or using washers that may allow the nut to back off.

 

I have seen a metal cap that fits over a nut and it has points on it that would extend the castle nut so that the key would fit through it. One came with the tie rod that fastens to the pitman arm ( left inner tie rod I think ) But I dont know what the fancy cap is called.

 

01 Ford expedition 2wd outter tie Rod castle nut torque spec?

 

Here you go. Might get better overall results posting in the Expedition forum for most things

 

Maybe this has been answered elsewhere but I thought I would share what I learned as I came across the same problem. I was replacing steering components on my 2002 2WD and ordered a Center link (AC3Z-3304-M), an Inner tie rod (AC3Z-3A130-M); and then outer tie rods (Right - AC3Z-3A131-M and Left - AC3Z-3A130-N). Installed and was left with the same problem where the cotter pin would not intersect the castle nut as shown below. This was at all 4 locations (inner and outer).



I verified part numbers with the dealer per my VIN. They mentioned there were a couple options of nuts to go with that assembly but initially didn't provide any details. The dealer initially suggested going with W712367 S440 for the nuts (4 locations) and W710907 S439 for some retainers (4 locations) that go on top of the nuts. Those ended up being too big for my application (for a thread size that was larger in diameter than mine). I returned those and went with the other option of W711373 S440 for the nuts (4 locations) and W711374 S439 for the retainers. This was exactly what I needed. What was on mine originally is shown on the left (with a shorter stud and a castle nut) and the new unit on the right (with a longer stud, a nut, and a retainer).



Hope this helps someone!

 

When I replaced everything with new OE, encountered the same issue and purchased grade 8 thick washers. One per did the trick.