So I decided to upgrade the steering on my XJ by installing the ZJ tie rod. Here are the parts I ordered.
-ES3096L tie rod end
-DS1312 tie rod
ES2079S adjustment sleeve

I installed this on my 1999 XJ and the tie rod end will not fit in my knuckle!! the stud of the tie rod end itself seems to be to large for the knuckle itself. Am i doing something wrong? Any help is appreciated.

 

Got any pictures?

 

i dont have any pictures at the moment. But even if i did it wouldnt show much. I have the nut as tight as i get get it on the stud of the tie rod end.

 

Are you putting it in from the bottom and not from the top?

 

From the bottom. Just like the stock one

 

I cant get it far enough that the cotter pin can insert.

 

Is it tight in the knuckle? If so then just put some red thread locker on it and forget about the cotter pin.

 

Thata actually a good idea. Thanks!

 

I personally wouldn't ever use thread locker in place of a cotter pin on steering stuff. That's just asking for trouble! I would go find a castle nut that has deeper slots so that you can use a cotter pin. And yes, they do make them!


Another (safe) option (as long as it is close) would be to grind a little off of the bottom of your existing castle nut so that the nut will sit lower and the cotter pin can be installed. Just be sure to grind it flat!


Dennis

 

Maybe I'm missing something here.

The parts you mention are for what is called the drag link, and are for the
right (passenger) side of the ZJ, from the pitman to the knuckle. The
pictures in post #6 show the left (driver's) side knuckle.

 

They are the tie rod parts. I also ordered drag links and installed those fine

 

I misunderstood something. I didn't realize the ES3096L, which is used on the drag
link at the pitman, is also used with the ZJ tie rod, the bar that connects the drag link
to the driver's side knuckle. Sorry to add confusion.

 

^^^THIS^^^

 

That is horrible and unsafe advice. I'm not even going to ask why...

 

Try exchanging the tie rod end or comparing it to another one. Could be a bad or mislabeled part. You wouldn't believe the bad luck I've had lately with parts being put in wrong boxes or not fitting by just a smidge! Does any part of the cotter key hole show? If so a smaller diameter cotter key may work. Could also be what's called "tolerance build up". That's where your knuckle is built to the thickest dimension allowed, the hole in the tie rod is drilled to the shortest dimension allowed, the ball assembly in the tie rod is built to the thickest allowed, etc. All the parts are within spec but just barely and in the wrong direction causing your problem! Happens more than most people think. That's another reason to try/compare another tie rod end.