I never enjoy turning my 86' Rock over to any service shop. (i do most of the work myself) The problem is New York State inspection demands a front tire be pulled. This shop OVERTIGHTENED the right front, and the wheel lock broke as I attempted to remove it for a chassis lube. I know many tire shops have special tools to remove tires with lost lock keys, but this one has very little metal showing now. (Only the tapered part that holds the wheel on remains) The question is: would it be possible to make up a drill guide to weaken the stud, then attempt to break it off by pullling on the wheel. My only hope is to save the wheel. If I end up buying a new rotor,or stud thats ok. I shutter at the thought of buying a new wheel (s). Anyone, thanks for your input. Matt

 

Here's the best way to drill a front wheel stud: pop the cap off the hub and remove the hub/rotor and wheel together from the car. Lay the wheel face down and mark the stud that has the broken lock on it. Use a center punch to make a dimple EXACTLY in the center of the stud, and use that dimple as a centering guide to drill through the stud. KEEP THE HOLE STRAIGHT. Start with a 1/4" hole and make it around 1" deep, then go back and ream it out with a 1/2" bit. The "flange" part of the stud should come loose, just like when you drill out a rivet. You'll need to drill on through the stud to weaken the knurled section so it will slide on through the hub. When the 1/2" hole is about 3/4" deep you can flip the wheel over and use a hammer and some type of punch or bushing driver to knock the hub off the back of the stud. You don't want to just drive the stud through from the back, as it may damage the mounting hole on the wheel. Once the hub is off, the stud may just slide out...but you might have to cut the knurled section off with a die grinder. It depends on the wheel. If you're careful to keep your hole straight you can even just buy a stud and reuse the hub/rotor. Good luck with it,