WHEEL STUD REPLACEMENT

REQUIRED TOOLS	MATERIALS (Check manual for types, amounts and applicability)	TIME
Socket Set 3/8" Allen Jack (2) 3 to 5 lb hammers	New Wheel Stud(s) Open End Nut That Fits Stud 3/8"-1/2" stack of washers that fit over stud shank WD-40 or other lube	0.5 Hours

Since I have replaced two wheel studs due to breakage and one due to stripping, I decided I would show how I made the repair. (I make no claims that replacing your wheel studs in this same manner will result in no more damage or additional broken parts.  Use caution and judgment when performing these repairs)

These steps are for a 1997 Dodge Ram 1500 4x4.  The same basic methods should apply to stock 2500 and 3500 4x4 rams as well, after the front hubs are removed.  Two-wheel drive trucks should be similar once you can remove the broken stud.

First step is to remove the stud.  To get to the stud, put the truck on jack stands and remove the wheel.  Then, remove the brake caliper from the rotor by pulling the two 3/8" hex drive sleeve bolts holding the caliper to the axle.  Set the caliper aside, but do not hang it from the brake line!  If you have them, remove the retaining clips from the studs with the screwdriver and slide the rotor off.  You are now ready to remove the stud.

In my case, I turned the axle until the broken stud was to the rear of the truck and away from the mudguard.  Using a 5 lb hammer next to the stud and on the back of the hub, I beat on the end of the broken stud with a 3 lb hammer until it popped out the back.  You could also use a press, but I didn't have one.  Be careful as you can damage seals and bearings this way if you do not limit the force applied into the axle.  

Once the stud is removed, you can insert the new stud through the hub from the backside.  Place the washers over the stud and thread on an open-end lug nut. Spray on some penetrating oil (I used wd-40) onto the knurled section of the stud shank.

Begin to tighten the lug nut down.  Be careful when nearing the washers as to be sure they are going on flat and not riding on the corner of the stud shank.  Use a strong screwdriver between the studs and the hub to keep it from spinning while tightening the nut.

Once the stud bottoms out as you pull it through the hub, you are done.  Back the nut off and remove the washers.

Once the nut and washers are off, it is time to replace the parts in reverse order.  Replace the rotor and install the caliper and replace the sleeve bolts. Reinstall the wheel after rechecking the caliper bolts.

This entire procedure took me 30 minutes, in the dark no less!  It is really easy and requires minimal tools.