After installing a tie rod end, the cotter pin hole is misaligned. What should the technician do?

When a technician installs a tie rod end and discovers that the cotter pin hole is misaligned, the appropriate action is to adjust the nut until the hole aligns. This is crucial for ensuring that the cotter pin can be installed correctly to secure the tie rod end in place. Proper alignment of the cotter pin hole is essential because the pin helps prevent the nut from loosening due to vibrations and forces encountered during driving.

By tightening the nut to align the hole, the technician engages the tie rod end properly and ensures that the suspension system's integrity is maintained. This step is part of the standard procedure to ensure all fasteners are secure, which is critical for vehicle safety and performance.

Other actions may lead to unnecessary replacements or complications. For instance, replacing the tie rod end or steering knuckle may not address the underlying issue of misalignment and would be considered excessive if the adjustment of the nut can solve the problem. Loosening the nut until the hole aligns, while it may seem logical, could inadvertently lead to an insecure connection if not handled properly and does not guarantee the necessary tightness before securing the cotter pin. Thus, tightening the nut is the most efficient and correct approach in this situation.