Originally Posted by JimBlake

First, what you want to measure is from the flat surface that bears up against the end of the steering rack. So it's within the black oval on the old tie rod, but specifically the flat part not the end of the threaded stud. Also, if you have new washers, put the old washers on the old part, new washers on the new part, and measure with the washers in place and somehow tight together.

Then the outer part of the measurement is the centerline of the stud that fits into the knuckle. Problem here is that you'll have to square up that stud which is kinda visual and subjective.

It'll only get you pretty close, so I'd have the car aligned when you're done.

The old boot has probably been squashed into that position for years and sticks there. I think you'll see when you install it, the boot squishes out sideways as its pushed down, so it bulges out like the old one. The tapered part of that stud is what controls how far it goes into the knuckle.

Finally, you'll have to pull them apart in order to install the big rack boot over the end of the inboard tie rod. Set the length the way you have them sitting here, then count the turns when you unscrew the new parts to put the boot on.