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Parts/Tools
Instructions Breaking a wheel stud...The wheel stud on my passenger side front wheel fell victim to crossthreading. It took a long time of trying to drill it out (the lug nut was still attached) and then finally getting it to at least break off so I could get my wheel off. After that I drove around for probably 6 months with only 3 wheel studs because I didn't feel like paying a shop to do it. Well one day the time came for me to replace my axel, since it was on the same wheel I decided to do the stud at the same time. I had heard about a method of cutting the stud so I decided to try and do that way. You must take all the brake components off so you can get to the wheel studs. This is done by removing the wheel, brake caliper and bracket, and the rotor. I had to dremel off the rest of the broken wheel stud and punch it through the back of the hub but that is no problem. Next I found the best spot which is where the least tin is on the dust shield and about a 1x1 square out of that spot that would allow the wheel stud to enter.
I then took out a new wheel stud and stuck it in the hole to see about how much I would need to cut off. It was basically a 45* angle a little more than half way on one side of the stud.
To do this I used a Dremel with Gyros Super High Tensile (ST) Cutting Disc. The stud is made of very hard metal so it takes some time to cut it but its not too bad.
Now with the stud cut I placed it in the hole to line it up as best I could. You should be able to push it through with your bare hands.
I then put the rotor back on and took a lug nut and put it on so I could tighten it and the wheel stud would fit into it's correct spot.
I now have a perfect wheel stud in and it all took less than 15 minutes to do.
Notes
I have heard this method only works on the 88-91 Honda Civics but it may work on some other ones.
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