If the cotter pin hole does not align within the recommended torque range, what is the acceptable practice?

• A. Change washer and try again
• B. Re-torque to alignment
• C. Use a longer bolt
• D. Apply threadlocker

Answer: (A)

The important idea here is that the cotter pin must pass through its holes after the fastener is tightened to the specified torque. If the holes don’t line up at that torque, you don’t try to force a different torque or change the fastener geometry in a way that bypasses the spec. The correct approach is to change the washer (or its thickness) and re-torque to the same recommended value until the holes align and the cotter pin can be installed. This keeps the clamp load within the design limit while ensuring the locking mechanism works as intended.

Why the other options aren’t appropriate: re-torquing to achieve alignment could push you beyond the prescribed torque or not guarantee alignment at all, and it would compromise the procedure for this lock. Using a longer bolt changes the joint geometry and the preload, which isn’t allowed and can introduce other issues. Applying threadlocker doesn’t provide the required through-hole alignment for the cotter pin and can complicate maintenance and inspection.