Broken or stripped Ford wheel studs have always been a problem. This stems from the fact that the studs are of a softer material than the lug nuts. It is extremely easy to strip the studs by applying too much torque to the lug nuts, pulling the threads out of shape. Another cause for stripped studs is installing the lug nut with less than two-thread contact and not perfectly straight. When torqued, the threads are torn loose. This is not a complicated process and can be accomplished with basic tools with the exception of an air gun. It requires a high torque to draw the stud into the hub. The use of a long breaker bar is too risky due to side torque, which could bend or break the stud.
Raise and support the vehicle on jack stands. Remove the wheel/tire assembly using the ½-inch air gun. Remove the two bolts securing the brake caliper to the mounting bracket using a 3/8-inch drive socket. Lift the caliper off the rotor and suspend it from the spring using a suitable piece of wire.
Remove the two bolts in the back of the brake caliper-mounting bracket using a 3/8-inch drive socket. Remove the rotor by pulling it off the hub.
Knock the stud out of the hub with the hammer.
Spread anti-seize on all six washers so they will spin easily under the lug nut. Insert the new stud followed by the six washers and then the lug nut. Run the lug nut in by hand until tight.
Draw the stud into the hub carefully with short blasts on the air gun. Keep watching the head of the stud and draw the stud in just until the head of the stud is flush with the hub. Stop there or the air gun will break the stud off. Remove the lug nut and washers and apply a small amount of anti-seize to the threads of the new lug nut. Replace parts in reverse order of removal.
