A worn lug stud no longer provides the full amount of grip between the lug nut and the wheel. Although it is unlikely that one damaged stud will cause the wheel to come off, it's still important to replace damaged lug studs as soon as possible to avoid creating a dangerous situation. The studs on a 2005 Chrysler Town & Country only cost a couple of dollars, and you can replace them in a few minutes without the assistance of a professional mechanic.
Put the van in "Park" and firmly set the emergency brake. With a lug wrench, slightly loosen each lug nut on the wheel. Turn each nut no more than one half turn. This will make it much easier to remove the nuts once the van is jacked up.
Remove the jack from the trunk and place it under the designated jacking point approximately 6 inches toward the center of the vehicle from the wheel well. You'll see a crescent-shape notch in the frame where the jack is positioned. Alternatively, you can use a larger floor jack. Lift the vehicle until the tire is completely off the ground.
Finish removing the lug nuts and take the wheel off of the van. Place a flat faced wheel nut on the stud to avoid causing additional damage. Using a hammer, tap the nut to drive the lug stud towards the back of the hub. After several solid hits, it should be loose enough to pull out by hand. Discard the stud.
Push the new lug stud in from behind the hub. Gently tap it into place with a hammer. Do not hit it with excessive force. It won't go in all the way, since the end of the stud is designed to be pulled in, compressing the metal and creating a secure fit.
Place a stack of several flat metal washers around the front of the stud, followed by an open-ended lug nut. Do not use one of your regular lug nuts, as the pulling process would damage this nut so that it won't secure the wheel. Gradually tighten the lug nut with the lug wrench. Closely watch the back of the hub as the lug head pulls closer to the metal. When it is resting flat against the hub, stop tightening the nut. Remove the lug nut and washer.
Use this same process to replace any other studs that are damaged, then put the wheel back on. Tighten the wheel nuts and lower the van to the ground.
