Tie-rod End

[dhepper]

I recently replaced the steering gear in my 97 Avalon (65K). When I went to install the right side tie-rod end, the hole in the steering knuckle was too large - it measures about 1/16th of an inch greater in diameter than the left side. The castle nut went up the threads well above the holc for the cotter pin. How is this possible? Any ideas? I don't think the old tie-rod end had ever been removed and the hole did not look worn - it was symmetrical, not beat up looking, etc. A mechanic thought perhaps someone over-torqued the nut but I know that I didn't and I question if this could enlarge the hole in the cast steering knuckle. I've tried more than one of the proper size tie-rod ends and the result is the same. Any ideas? Thanks.

[rusty9]

bigger cotter pin and washer or 2? i didnt understand in your post but have you tried a brand name part like moog?