Castle nut inquiry

[Eagle_SX4]

I just replaced my drag link and tie rod ends on my truck and tightened everything up and went to put the cotter pins in place and the castle portion of the nut is below the cotter pin hole. How do I fix this? Maybe drill a new hole? Or are my the tapers in my spindle stretched somehow?

[eaglescout526]

Could always put a washer or two in to get the castle nut where it needs to be. 
 

I have noticed this issue on new joint parts these days. 

[derf]

Yep.  They're substituting some parts with others that are close but not quite right.

 

Stack a couple of washers to get the nut up where it needs to be.  Grade 8 would be better.  Less likely to deform.

[Eagle_SX4]

Found some grade 8 washers to make up the difference thanks for the replies.

[coolwind57]

We use washers all the time in Aviation to make up the difference.  The use of varying Washer thicknesses can be quite the puzzle to solve when you're torque specs are tight and that damn hole just does not want to line up.  

[75sv1]

I've stacked washer too. I also found some castle nuts of different heights. 

[JZLAJeep]

Lock nut instead?

[AZJeff]

Hardened washers are the way to go here.  
 

Or, as others mentioned, self-locking nuts.  Newer vehicles have moved away from castellated nuts to self-lockers, to simplify production, so I would feel confident in that solution.