Since this thread is still going along does anyone know why my service manual says not to line up the groove in the tie rod tube with the clamp opening? It looks like the one pic A12 has posted the tube is that way.

But, as A12's pics show, "as built" differs. There might even have been a plant worker who did it correctly rather than quickly.

I've often pondered that also. Best logic I see is that the bolts threads could bind, or get marred, on the edge of the slit.

As fare as the cotter pins go based on what I remember of originals & the pics A12 provided they look to have a slightly pointed round head & equal length legs,not the P head type with unequal length legs & the starter bend at the end of the long leg like the later day NOS replacement ones pictured.