What is the acceptable practice if the cotter pin hole does not align within the recommended torque range?

When the cotter pin hole does not align within the recommended torque range, the acceptable practice is to change washers and try again. This approach acknowledges that the alignment issue may be due to insufficient spacing or improper load distribution caused by worn or inappropriate washers. By replacing them with new ones that better accommodate the fit, you can help achieve the necessary alignment for the cotter pin hole.

This practice ensures that the components are secured properly without compromising safety or component integrity. If the hole is misaligned, continuing to use the same washers may exacerbate the problem, whereas changing them facilitates a more effective solution.

Other methods, such as replacing the bolt or increasing torque, could lead to additional issues like thread stripping or component failure, while re-torquing to the maximum limit does not address the root cause of misalignment.