Tie Rod End - Outer

This procedure covers the removal and replacement of the outer tie rod end on a 2005 Dodge Viper, including disconnection from the steering knuckle and adjustment for proper alignment reference.

Warnings

Tools required

Parts

• Outer tie rod end × 1 — Use OEM specification or Moog ES3603RL (right) / ES3602RL (left)
• Cotter pin × 1 — 1/8" diameter, appropriate length

Preparation

1. Park vehicle on level surface and engage parking brake
2. Loosen wheel lug nuts on the side being serviced while vehicle is on ground
3. Raise front of vehicle with floor jack at designated lift point
4. Support vehicle securely on jack stands placed at appropriate frame locations
5. Remove wheel completely

Procedure

1. 1

   Mark alignment reference position
   Before loosening any fasteners, use white paint marker or tape to mark the position of the outer tie rod end relative to the inner tie rod shaft. Make a line across both the outer tie rod end body and the inner tie rod threads. This reference mark will help maintain approximate toe setting during reinstallation and minimize alignment deviation.
2. 2

   Remove cotter pin from castle nut
   Locate the castle nut securing the outer tie rod end to the steering knuckle. The cotter pin passes through the castle nut slots and the tie rod end stud. Use pliers or wire cutters to straighten the cotter pin ends, then pull the cotter pin out and discard it. If the cotter pin is corroded, it may need to be cut or drilled out.
3. 3

   Loosen tie rod end castle nut
   Using the correct socket or wrench (verify size against vehicle spec), loosen the castle nut on the outer tie rod end stud but do not remove it completely. Leave the nut threaded on 3-4 turns to protect the threads and contain the tie rod end when the taper breaks free. Apply penetrating lubricant around the taper if corrosion is present.
4. 4

   Separate tie rod end from steering knuckle
   Position a tie rod end separator (pickle fork or ball joint press style) between the steering knuckle arm and the tie rod end body. Strike the separator with a hammer to drive the wedge into the taper joint, or tighten the press-style tool until the taper releases. The tie rod end will pop free from the knuckle with an audible crack. Once separated, remove the castle nut completely and pull the tie rod end stud out of the knuckle.
5. 5

   Loosen tie rod lock nut
   Locate the lock nut on the inner tie rod where the outer tie rod end threads onto the shaft. This is a jam nut that secures the outer tie rod end position; verify its size against vehicle spec. Use the correct wrench to loosen this lock nut but do not remove it completely. Leave it threaded on the inner tie rod to serve as a stop when unthreading the outer tie rod end.
6. 6

   Count threads and remove outer tie rod end
   Count the number of exposed threads visible between the outer tie rod end and the lock nut, or count the number of full rotations as you unthread the outer tie rod end. This serves as a backup to your alignment reference mark. Thread the outer tie rod end counter-clockwise off the inner tie rod shaft. Keep track of the rotation count. Once removed, inspect the threads on the inner tie rod for damage or corrosion. Clean threads with a wire brush if necessary.
7. 7

   Install new outer tie rod end
   Thread the new outer tie rod end onto the inner tie rod shaft clockwise. Use your alignment reference mark as a guide, threading the new tie rod end until the mark you made is approximately aligned. Alternatively, use the thread count or rotation count from removal. The goal is to get the new tie rod end positioned as closely as possible to the old one's position. Do not tighten the lock nut yet.
8. 8

   Install tie rod end into steering knuckle
   Insert the tie rod end stud into the steering knuckle taper hole. Ensure the taper is clean and seated properly. Thread the castle nut onto the stud by hand, then tighten using the correct socket or wrench (verify size against vehicle spec) to the specified torque.
   Torque spec

   Tie Rod End Castle Nut55 Nm (41 lb-ft)
9. 9

   Align castle nut slots and install cotter pin
   After torquing the castle nut, check whether the slots in the castle nut align with the hole in the tie rod end stud. If the slots do not align, tighten the nut further (never loosen) until the next slot aligns with the hole. Maximum additional tightening should not exceed 1/6 turn (60 degrees). Insert a new cotter pin through the hole and bend the ends over to secure it. One end should wrap around the nut, the other bent outward or upward.
10. 10

    Tighten tie rod lock nut
    While holding the outer tie rod end body steady with a wrench to prevent rotation, tighten the lock nut against the outer tie rod end using the correct wrench (verify size against vehicle spec). Torque the lock nut to specification. This locks the outer tie rod end position on the inner tie rod shaft.
    ℹ️Final torquing of the tie rod lock nut should be performed after professional wheel alignment to lock in the correct toe setting.
    Torque spec

    Tie Rod Lock Nut68 Nm (50 lb-ft)
11. 11

    Reinstall wheel and lower vehicle
    Mount the wheel onto the hub and thread all lug nuts by hand. Lower the vehicle until the tire just contacts the ground to prevent wheel rotation. Torque the lug nuts to specification in a star pattern.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)

Reassembly

1. Remove jack stands and lower vehicle completely to ground
2. Perform final torque check on wheel lug nuts with vehicle weight on ground
3. Test steering operation before driving to ensure tie rod end is properly seated and secure

Verification

• Verify castle nut is properly torqued and cotter pin is securely installed and bent
• Check that tie rod lock nut is tight and outer tie rod end does not rotate on inner tie rod shaft
• Turn steering wheel lock-to-lock while stationary and verify smooth operation with no binding or clicking noises from the tie rod end
• Check for any play in the tie rod end by grasping the tire at 3 and 9 o'clock positions and pushing/pulling; no looseness should be felt
• Schedule professional wheel alignment immediately, as toe setting has been disturbed and will cause tire wear and handling issues

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