In a previous article I talked about removing cotter pins.
In this article, I will discuss installing cotter pins.
The service manual will specify a range of torque values for the castle nut. For example, it might list something like 22 to 39 ft-lbs. I select the torque value at the bottom of the specified range. In this example, I would torque the nut to 22 ft-lbs. Next I use a socket or a wrench to turn the nut just enough to align a slot in the castle with the hole in the part. The castle nut should always be tightened to align the slot. The nut was initially torqued to the bottom of the range. If it is loosened to align a slot with the hole, it will be too loose.
Always use a new cotter pin. They are inexpensive and readily available at the hardware or auto parts store. I bend half of the pin over the top of the nut and trim it to length. I trim the other half of the pin short and bend it down the side of the nut. In some cases, the service manual may give a specific method for bending the ends of the cotter pin.
Diagonal cutters are my favorite tool for installing cotter pins.