[rcmiller32]

Replacing tie rod end bushings in a 2000 Chrysler 300M. When tightening the passenger side bolt holding the tie rod to steering rack, the bolt bottoms out before compressing the tie rod end bushings. Appears to be almost 1/4 inch gap. Drivers side bolt tightens down properly and compresses bushings against sleeve.
Both bolts are the same length, 68 mm.
The steering rack was replaced 12,000 miles ago with a rebuilt and the tie rods and bushings were replaced. Now the passengers side tie rod bushings have failed. I suspect this early failure can be contributed to lack of compression on the bushing.
Is it possible that Chrysler used different length bolts to attach tie rods to the steering rack on some models?

[TxGreaseMonkey]

Yes. It sounds like the bolt they gave you is too long.

[CaptainRich]

I can't imagine using different sizes here.
It's either that or the threads are damaged and the bolt is hitting that area before the torque spec is met.
I'd try running an appropriate thread repair die into the threads and retry the bolt.