How to Fix a Broken Rear Wheel Stud on a 2004 Ford Focus

The wheel studs in your 2004 Ford Focus attach the wheel to the brake drum and hub assembly with torque evenly distributed across the surface of the drum. When one of the studs breaks, the torque is not evenly distributed and the remaining wheel studs experience a higher load. This can eventually lead to wheel stud failure in the remaining three studs. Replacement of a broken wheel stud is well within the capability of the average home mechanic and the repair will take about an hour to complete.

Instructions

1

Loosen the lug nuts 1/2 turn, on the wheel that has the faulty bearing, using a lug wrench. Wedge wheel chocks behind the rear wheels and set the parking brake firmly. Raise and support the front of the Focus using a floor jack positioned under the center of the front subframe and jack stands under each side of the subframe for safety.

2

Remove the wheel. Remove the dust cover over the hub nut located in the center of the brake drum using a hammer and punch to pry it out of the hub. Remove the 30-mm hub nut using a socket and ratchet. Slide the drum and hub assembly off the axle.

3

Lay the drum and hub assembly with the wheel studs facing up on a solid work surface. Drive the broken stud out of the drum and hub assembly using a hammer and punch.

4

Apply a small amount of grease to the threads of the new stud. From the inside of the drum, slip the new stud into the hub and drum assembly and tap it into place using the hammer. Apply a small amount of grease to the contact surface of the tool and to the area of the drum around the new stud. Screw the wheel-stud installation tool onto the new stud. Tighten the installation tool onto the stud, using a 19-mm wrench, until the flange of the stud is flush against the inside of the drum and hub assembly.

5

Reinstall the drum and hub assembly onto the axle. The hub nut is a stacked washer design that should only be reused a maximum of four times. If the nut has been reused more than four times, replace it. Reinstall the hub nut and torque it to 173-foot pounds using a torque wrench.

6

Reinstall the wheel and torque the lug nuts to 94-foot pounds. Remove the jack stands and lower the jack until the wheels are on the ground. Remove the floor jack and test drive the Focus. Re-torque the lug nuts one additional time after the test drive