Tie Rod End 04 4x4

[zombienerd]

I just replaced both inner and outer tie rod ends on the driver's side. I can't find the torque spec for the outer end castle nut anywhere. The forum search isn't very friendly for generation specific answers lol.

If I tighten the castle nut 'all the way' until it's snug, the cotter pin hole is a good 3-4mm below the castle nut, which doesn't make sense in relation to every video and picture I've seen.

Any help or ST specific guides would be VERY appreciated. I've been fighting with this front end for over a week now (also replaced the driver's CV).

A link or PM to the service manual for this truck would also be VERY appreciated

 

[swshawaii]

TRE Castle Nuts 52 ft/lbs. (Step 9)
https://www.scribd.com/document/335099676/ball-joint-8212-lower-4wd-removal-and-installation-pdf
Toe adjusting nuts 59 ft/lbs. (Step 7)
https://www.scribd.com/document/335100055/wheel-alignment-general-procedures-pdf

Front Suspension Specs (4x4)
https://www.scribd.com/document/335099511/front-suspension-8212-4x4-specifications-pdf

Sure you're using the correct TRE's? (Moog ES3667, etc.)
http://www.rockauto.com/en/catalog/ford,2004,explorer+sport+trac,4.0l+v6,1427789,steering,tie+rod+end,7428?a=Referer+www.google.com+URL+/

 

[sr139fox]

I always tightened them pretty tight. The carter pin must go through the castle nut slot. If it does not, I have used a flat washer as a spacer. Dave P.