Cotter Pins

[MSGia]

Good afternoon all, I am wrapping up suspension work on my Ranger, I am tightening my drivers side lower ball joint castle nut, and I can’t seem to make the cotter pin hole line up. I probably tried 10 times loosening and reinstalling the nut, but the cotter pin won’t fit through. What should I do here? Is it okay to use a smaller cotter pin than provided, or is there any other solution?

 

[Curious Hound]

If it's close enough that a smaller diameter cotter pin will fit, then you should be able to bump it a tiny bit more for the right pin to fit. A longer breaker bar, or maybe tap the wrench with a dead-blow hammer. Another idea might be to put a thin washer under the nut. This will make a different slot line up with the hole in the stud.

 

[MSGia]

If it's close enough that a smaller diameter cotter pin will fit, then you should be able to bump it a tiny bit more for the right pin to fit. A longer breaker bar, or maybe tap the wrench with a dead-blow hammer. Another idea might be to put a thin washer under the nut. This will make a different slot line up with the hole in the stud.

Thanks. I might try the washer. The only reason I didn’t want to try to tighten it more was because I didn’t want to over torque it, it’s already at 115 foot pounds, but would it matter?

 

[ekrampitzjr]

Could some debris be blocking the cotter pin hole inside the bolt? Maybe see if you can push a smaller cotter pin through to make sure the hole is clear. Then use the correct cotter pin. A gentle tap on the loop end of the cotter pin might help get it in place.

 

[MSGia]

Could some debris be blocking the cotter pin hole inside the bolt? Maybe see if you can push a smaller cotter pin through to make sure the hole is clear. Then use the correct cotter pin. A gentle tap on the loop end of the cotter pin might help get it in place.

I don’t think there is debris. It is a new ball joint, and before I installed the spindle I had the cotter pin sitting in there so I didn’t lose it. I also tried to tap the supplied cotter pin in, it won’t budge, the hole is about half covered.

 

[alwaysFlOoReD]

I would be inclined to tighten it up enough to line up. It might be an extra 2°. Usually torque values have a fairly large range. Maybe try slightly less torque first.

 

[85_Ranger4x4]

I would be inclined to tighten it up enough to line up. It might be an extra 2°. Usually torque values have a fairly large range. Maybe try slightly less torque first.

 

[Curious Hound]

I mean, yeah. I agree, too.

 

[SenorNoob]

^This is the way.

 

[JoshT]

^ What they said.

If you've torqued to 115, I wouldn't have a problem backing off slightly to align the pin hole. I don't remember the last time I even used a torque wrench on a ball joint or tie rod end. Usually just tighten them up good and align the pin hole.

 

[SenorNoob]

Is it done yet?

 

[MSGia]

Is it done yet?

Yes it is done Probably tighter than 115 foot pounds but it’s on.

 

[SenorNoob]

It'll be fine as long at the nut/stud didn't strip. The thread would give way before the stud broke.