A particular component is attached to the aircraft structure using an aircraft bolt and a castellated tension nut combination. If the cotter pin hole does not align within the recommended torque range, what is the acceptable practice?

1) Use a larger cotter pin to align the hole.
2) Use a smaller cotter pin to align the hole.
3) Use a different type of fastener to attach the component.
4) Adjust the torque on the tension nut until the hole aligns.

The acceptable practice when a castellated tension nut does not align with the cotter pin hole is to adjust the torque on the tension nut until the hole aligns, ensuring aircraft component integrity and safety. The correct option is 4, which is to Adjust the torque on the tension nut until the hole aligns.

Explanation:

The correct option is 4, which is to Adjust the torque on the tension nut until the hole aligns. When encountering a situation where a castellated tension nut does not align with the cotter pin hole within the recommended torque range during aircraft maintenance, the acceptable practice is not to use a larger or smaller cotter pin or to choose a different type of fastener.

Instead, one should adjust the torque on the tension nut until the hole aligns. It is critical to maintain the integrity of the aircraft components and ensure they are properly secured according to specifications, without compromising safety or deviating from standard practices.