This procedure covers the removal and replacement of the outer tie rod end on a 1966 Chevrolet Corvette with 327ci V8, including proper separation from the steering knuckle and alignment preparation.

Warnings

Tools required

Parts

• Outer tie rod end × 1 — Use OEM specification or quality aftermarket
• Castle nut for tie rod end × 1 — Usually included with tie rod end
• Cotter pin × 1 — 1/8" diameter x 1.5" length

Preparation

1. Park vehicle on level, solid surface and apply parking brake firmly
2. Place wheel chocks behind rear wheels
3. Loosen front wheel lug nuts 1/2 turn while vehicle is still on ground
4. Raise front of vehicle with floor jack at frame cross member
5. Support vehicle securely on jack stands placed under frame rails
6. Remove front wheel completely

Procedure

1. 1

   Mark existing tie rod position
   Before loosening anything, use a white paint pen or marker to mark the exact position of the outer tie rod end where it threads onto the inner tie rod. Make a reference line across both the outer tie rod end body and the inner tie rod shaft. Count and record the number of exposed threads visible between the outer tie rod end and the jam nut. This ensures approximate toe setting is maintained during reassembly.
2. 2

   Apply penetrating oil
   Spray penetrating oil on the castle nut threads at the steering knuckle, the jam nut threads on the inner tie rod, and where the outer tie rod end threads onto the inner tie rod. Allow 10-15 minutes for penetration if components show rust or corrosion.
3. 3

   Remove cotter pin
   Locate the cotter pin securing the castle nut at the steering knuckle. Straighten the bent ends of the cotter pin with pliers, then extract it completely. Discard the old cotter pin.
4. 4

   Loosen castle nut
   Using a 7/8" wrench or socket, loosen and remove the castle nut from the tie rod end stud at the steering knuckle. Do not remove the nut completely yet; back it off until it is flush with the end of the stud threads to protect threads during separation.
5. 5

   Break taper at steering knuckle
   Position the tie rod end separator (pickle fork) between the steering knuckle and the tie rod end. Strike the separator firmly with a ball peen hammer to drive it into the taper joint. Alternatively, leave the castle nut loose on the stud and strike the steering knuckle boss sharply with a hammer while applying upward pressure on the tie rod end to shock the taper loose. Once the taper breaks free, remove the castle nut completely and pull the tie rod stud down and out of the steering knuckle.
6. 6

   Loosen jam nut
   Locate the jam nut (lock nut) on the inner tie rod where the outer tie rod end threads on. This nut locks against the outer tie rod end body. Using an adjustable wrench or 1/2" wrench, loosen the jam nut several turns but do not remove it completely. It will remain on the inner tie rod shaft.
7. 7

   Remove outer tie rod end
   Grip the outer tie rod end body with an adjustable wrench and unthread it counter-clockwise from the inner tie rod shaft. Count the number of complete turns required to remove it and record this number. Remove the outer tie rod end completely along with the jam nut.
8. 8

   Clean inner tie rod threads
   Use a wire brush to clean the threads on the inner tie rod shaft where the outer tie rod end was removed. Remove all dirt, rust, and old thread sealant. Inspect threads for damage. If threads are damaged or stripped, the inner tie rod must also be replaced.
9. 9

   Install jam nut on new outer tie rod end
   Thread the jam nut onto the threaded shaft of the new outer tie rod end, running it down toward the ball joint end. This stages it for proper positioning during installation.
10. 10

    Thread new outer tie rod end onto inner tie rod
    Thread the new outer tie rod end onto the inner tie rod shaft clockwise. Thread it in the same number of turns counted during removal, or until the alignment marks you made line up approximately. The goal is to return to the same position as the original, maintaining approximate toe setting. Leave the jam nut loose for now.
11. 11

    Install tie rod stud into steering knuckle
    Insert the tie rod end stud up through the hole in the steering knuckle. The taper on the stud must seat fully into the tapered hole. Push upward firmly to start the taper engagement.
12. 12

    Install and tighten castle nut
    Thread the new castle nut onto the tie rod stud and tighten firmly to draw the tapered stud fully into the steering knuckle. Tighten the castle nut to 35 ft-lbs. If the castle nut slots do not align with the hole in the stud at this torque, tighten further (never loosen) until the next slot aligns with the stud hole.
13. 13

    Install new cotter pin
    Insert a new 1/8" cotter pin through the castle nut slot and the hole in the tie rod stud. Bend the ends of the cotter pin over in opposite directions to secure it. Trim excess length if necessary, leaving enough material to prevent the pin from backing out.
14. 14

    Tighten jam nut
    Hold the outer tie rod end body stationary with one wrench while tightening the jam nut against it with another wrench. Tighten the jam nut firmly to lock the outer tie rod end in position. The jam nut must seat tightly against the outer tie rod end body to prevent the tie rod from turning during operation.

Reassembly

1. Reinstall wheel and thread lug nuts on by hand
2. Lower vehicle until tire touches ground but weight is not fully on suspension
3. Tighten lug nuts in star pattern to 80 ft-lbs using torque wrench
4. Lower vehicle completely and remove jack stands
5. Recheck lug nut torque after vehicle is on ground

Verification

• Verify castle nut is properly torqued and cotter pin is installed correctly with ends bent over
• Verify jam nut is tight against outer tie rod end body
• Grasp tire at 3 and 9 o'clock positions and attempt to move in and out - there should be no play at the outer tie rod end
• Have vehicle professionally aligned immediately, as toe setting will be incorrect after tie rod replacement
• After alignment, test drive at low speed in safe area and verify steering response is normal with no pulling to either side

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