torquing LBJ & TRE stud nuts. cotter pin not lining up. wtd?

So the few times I've done this on truck, when torquing the lower ball joint, or even tie rod end stud nuts, the cotter pin hole never seems to line up. I get lucky a couple times and it lines up like when installing a new one. But the old ones never seem to line up again. So on one side I torqued it to 105 foot pounds, but the hole didn't line up to put the cotter pin in...

What do you guys do? Tighten the shit out of it till it lines up on the next notch? Or back the nut off a little and insert pin? Or pop stud loose and try again?

I backed off the nut but it instantly came free hand loose, but I put the pin in. I did try tightening more, but that's freaking tight past 105 so I didn't go more...

I'm unsure if/how that affects the "stud turning torque".
What should I do? Is there a method?

Pop ball joint loose and re-tighten? Starting just below 100 foot pounds and increase till it lines up?
Call it good and it should jiggle tight driving?
Over tighten it as is and install cotter pin on next notch?

 

You can tighten it up to 60 deg past the point of recommended torque to line up the cotter pin, per Toyota.

 

Just keep cranking it. There are a lot of notches in that castle nut so it shouldn't need to go far.

 

Alrighty cool. Thanks guys. Was really bugging me to death. I actually popped the ball joint loose again and tightened to about 85. I think it stops at 105 like right in the middle of the castle nut notch. I was just unsure if it would affect the stud turning torque or not. Sounds like not. So I'll probly tighten her up when I get back home. Going in for alignment right now. Or is it ok at ~85?

 

85 will be fine