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I personally always use a new Castle nut on anything. My torque rods came with the nuts and cotter pins so I used them but i would've gotten new ones if they hadn't. If you hit on the nut to release the end I'd definitely replace it. If you hit the lug with the tapered hole to release the end...
I did all four of my lowers without removing the tires. Just make sure your on flat ground. If the rears are at different levels when the new one is installed, the rubber will be constantly stressed when on flat ground. This comes into play more for the uppers if done by the TMs, but is still a...
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