Gap between Upper control arm and ball joint castle nut

Today I replaced both of my upper ball joints on my 03 tacoma, 3.4L, 4 door with a 3inch lift, I used Toyota OEM parts (#43316-39016) and when I did the passenger side I overtightened the castle nut past the cotter pin holes on the ball joint. when I noticed this I then backed the castle nut off to where it aligned with the cotter pin holes but there was a gap that remained between the UCA and castle nut. Should I retighten it to remove this gap or is this normal and it will settle when the suspension flexes?

 

Do NOT leave it like that! Was there a washer under the castle nut before? Looks like you need a good hardened washer under now, in any case. Torque the nut to the lower end of spec, then tighten as needed until the cotter pin can be installed.

 

There was no washer before which is why I was concerned with the gap that i have now, ill probably have to put one in now though. And when I tighten it up to spec the cotter pin hole is way above the slots on the castle nut.

 

I am having the same issue. Is it the correct ball joint? Also, what did you end up doing with it?

 

They were the correct ball joint I ordered them from Toyota directly I just over tightened it, I ended up putting a few grade 8 washers in to take up the gap. It has been that way for two years and 30,000 more miles and while not perfect it has so far held up well and I've not had any problems even with trail rides.

 

Need to clean up that rust too while you're in there.

 

I just took a few pictures so you can see how it has held up.

 

Thanks, I ended up doing the same for mine as the second ball joint I bought also had the gap