Outer tie rod stud bottoming out

Hi all.

I am replacing the outer tie rod on my 2006 2wd Tundra. When I am trying to torque down the castle nut on the tie rod stud, the threads are bottoming out. I suspect that the tapered hole in the steering knuckle may be worn, but I am not sure. The original tie rod was replaced before I got the truck, so I have no way to compare the new part with the OEM part to see if the taper and thread length is the same. The old tie rod that I just pulled off was installed with a washer on it, so I suspect that they ran into the same problem and fixed it with a washer, but that seems like it would just lead to more problems.

I am sure that the new tie rod is the correct part for the truck (NAPA p/n ATM SE3861R). Is there anything that can be done other than replacing the entire steering knuckle?

 

First, welcome
Second, pictures help a lot... I mean a lot.
Third, unless someone on here has replaced theirs with the same Napa part (most are not) it will be difficult to say. I replaced mine with TRQ PSA55149

 

What does it mean, "the threads are bottoming out on the nut"?

 

I assume it means they're running out of threads on the tie rod where it comes through the knuckle - as if the threads aren't cut far enough or the diameter of the tapered portion is too small

 

Use a thick washer to space the nut up. I see this every now and then with aftermarket tie rods.

 

Obviously, something is not right: either the tapered hole in the knuckle is too large or the tapered shaft on the tie rod end isn't made to OEM spec (it's either too long or too narrow).

The knuckle doesn't wear out from use, time, or miles. So if the hole is too big it's because someone hogged out the hole to make an incorrect part fit. If that's the case, you need a new knuckle. The good news is that since this is not a part that wears out, you can get one used and it will perform as good as new. (They're all over eBay for $200 and under)

If the shaft on the TRE is too long or narrow, you just need the correct part. It looks like you can get an OEM TRE for about $45 from any online Toyota dealer. Personally, that's what I'd do... and return the one from NAPA. If the OEM part doesn't fit properly, then you know you need to replace the knuckle.

 

TRE's are usually replaced in pairs. What does the other side look like? If it has a washer too, then it's more likely the TRE being out of spec than the knuckle being the problem. If it does not have a washer. then it's more likely the knuckle.