Now I'm started to get miffed with Total Control...they keep sending email messages with "stock" answers like I'm some dweeb that doesn't know what I'm doing... They have mismarked or mis-shipped either the inner tie rods (which I have already modified) or the tie rod adapters that fit to the center link. The minor diameter on the adapter is .46 and the minor diameter on the inner tie rod is .45...so the adapter doesn't nest or tighten down on the tie rod stud...just spins and is "sloppy"...
If the adapter is tapered, you need to exert pressure on the tie rod to push all the parts together to keep the stud from spinning. I generally use a big pair of channel lock pliers in one hand, and the castle nut in the other. Then, use a ratcheting wrench to tighten it and align the castellations to the cotter pin bore.
You also need to keep the tapered parts meticulously clean of oil and grease for the taper to work properly. Clean them with alcohol if contaminated. With a clean taper you should be able to pass it through the hole, pull on the threaded end to set the fit and it won't turn.
I "bench nested" the adapter onto the tie rod end by pressing it on with a socket in the old vice which seemed to work ok. Still waiting for correct outter tie rods and universal to arrive...might call them today. In the meantime I did replace the vacuum wiper motor with a very nice electric unit from New Port Engineering. I was quite impressed how it perfectly fit in place of the old motor. I was hoping to be able to use the original bezel with their switch but that didn't quite work out.
The inners are getting "lonely"... it's been a week since I emailed them and no response. Gonna call them tomorrow...frustration is building...
So Total Control finally got back to me and it turns out that my '63 V8 spindles have had the steering arm tapers reamed to fit Granada tie rod ends....UGH! I guess it's just another example of the crap job that was done by the PO....or maybe he got a screaming deal on the spindles and just fitted tie rod ends that would match the taper? Who knows? Seems like I'll be doing the same...oh, and no doubt it will wind up costing me more...! Well, did more research and it seems that only the '63 uses the the same tie rod end taper on the steering arm as the Granada/Versailles...so I guess I have to take back my condemnation of the PO...
OK, need some advice from some of you steering gurus/magicians: I have most of it done now (though still waiting on the replacement universal that goes on the steering box...over a month and 3 reminders...!) but the stud from the tie rod protrudes up through the steering arm to where, when the castle nut is torqued, the hole for the cotter pin does not go through the cutouts (nomenclature? turrets? ha!) on the nut. My question is should I use some grade 8 washers between the steering arm and nut so the cotter pin goes through like it should or just leave it be???
Right, that's usually what you do, but it also means the tie rod stud's too long. See if you can find the proper taper and stud length to match your car better. I've never seen anyone lift a castle nut with washers because it's just not done. Taller castle nut or shorter stud are your only two choices, IMHO.
There is a third choice, that may be warranted if the position of that nut is correct, drill a new hole. The taller nut is easier.
Are you satisfied with the latest rod ends? One way to explain your nut problem is if the taper didn't match the taper in the steering arm, i.e., if it didn't seat at the proper place. If you are satisfied, then some washers would get you driving again; be certain that they clear any taper showing below the nut.
Stacking washers on a tapered fitting is NOT recommended. Every bolt is, in reality, a spring. As the spring gets longer, it becomes easier to stretch, increasing the likelihood of the taper moving under load, leading to failure. Washer stacking is only allowed with static loads.
I appreciate the input...looks like I'll be looking for a taller castle nut....that should be "interesting"! I might even have some and just have to start digging. The taper/tie rod are correct.
I did find one taller castle nut that worked out well and fit properly to preclude any backing off. Unfortunately I had only one...found 4 others but they are all the same height as the one provided, 1/2". After spending 2 hours on the internet searching for a taller one I finally gave in and emailed Total Control Products asking them for advice (and asking where is my universal joint for the fourth time). I guess I could try and find another old/OEM castle nut but how long will THAT take (though I do belong to a Falcon forum)??? Makes me wonder if my vehicle has been the first one to encounter all this?...Or the first one attempted?....I doubt that... There are tapered sleeves you can get (from Mustang Steve) to convert Mustang tapers to Granada tapers...I just recently found this out...Feel like I'm in the Twilight Zone at times, ha!
