When installing a slotted nut on a tie rod end or ball joint, what should you do if the cotter pin hole does not align with the slot?

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Multiple Choice

When installing a slotted nut on a tie rod end or ball joint, what should you do if the cotter pin hole does not align with the slot?

The purpose of a cotter pin with a slotted nut is to lock the nut in place by passing through a hole in the nut and a slot in the stud. If that hole and slot don’t line up, you can’t pass the pin, so the locking mechanism won’t work. In that situation you must not use the cotter pin. Recheck the nut orientation and torque to see if you can rotate to a position where the hole aligns with the slot, and if alignment cannot be achieved, inspect or replace components as needed. Forcing a pin or drilling a new hole would weaken the parts and compromise safety, so those options are not acceptable.

The purpose of a cotter pin with a slotted nut is to lock the nut in place by passing through a hole in the nut and a slot in the stud. If that hole and slot don’t line up, you can’t pass the pin, so the locking mechanism won’t work. In that situation you must not use the cotter pin. Recheck the nut orientation and torque to see if you can rotate to a position where the hole aligns with the slot, and if alignment cannot be achieved, inspect or replace components as needed. Forcing a pin or drilling a new hole would weaken the parts and compromise safety, so those options are not acceptable.

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