Very productive day in the garage, getting close to the first drive of the Dart and on the last stud I was tightening on the rear wheel, the flipping stud spun on me and the nut won't back off.

A little background... the rear brakes are Ford disk brakes. The nuts are acorn style (closed) with a lock nut (which requires a key) for each wheel.

Tightening them on by hand, thought it was tightening fine, but stud started spinning. All I can imagine is that the splines on the back side of the stud have not engaged the disk. Nut was going on a little tight (just beyond what I could do with my fingers), so now I can't back it off either because the stud is spinning.

All I can think to do is remove the other 4 nuts and "wedge" between the mounting face of the wheel and disk hat to hopefully get the stud splines to grab.

This is on a D60 with Torino ends for the disk kit.

IF........You can wedge a bit of pressure on the nut/stud and use a high rpm air gun..the lugnut may back off...small prybar..careful not to damage wheel....

Wheel damage is the biggest concern since these are custom offset wheels.

There is no thread showing. The only place I have to wedge is on the "hat" of the disk between the face of the wheel.

Wish me luck...

Just pull on the wheel opposite where the stud is while you try to undo that lug nut. (With other 4 nuts already removed now)

Tried that... no luck. I am done for today. Tried the impact too, no luck. No good way to wedge anything between the wheel and disk.

This could not be any worse. The nut is on far enough that there are no threads showing and the wheel is pretty much seated against the disk. Very little wiggle room. The nut is into the taper/seat of the wheel.

I can't believe this. I guess I never put a nut on that stud in the 10 years this rear has been under the car. Only ever used three as I was just rolling the car around.

you'll need a 3rd hand but if 4lugs are off, use the tire/wheel for leverage on the stud and try the impact

Use a die grinder with a carbide burr and just grind away at it until the nut is gone.

Here is your best tip: Take a center punch and mark the middle of the nut or stud,whichever is exposed. Now drill down the middle of it until its gone. Had this happen years ago with a nice Keystone wheel , no damage.

Thanks for the tips. Yes, I meant to say axle flange, not disk.

This stuff is all brand new. I am thinking the stud was not seated/pulled into the axle flange, hence the issue.

It happens to to be the key nut, so that complicates things more.

I'm not sure if I can get to the back of the stud or not. Possibly if I destroy the disk dust shield. But the parking brake shoes, etc. might get in the way as they are internal design.

I don't see a way to grind the nut off. I'll get a shot with the camera tomorrow, but I am dealing with American Racing Torque Thrust II wheels, 11" wide with 5.5" backspacing.

Might be able to drill it out... not sure yet. Definitely no burs and/or grinding especially since the nut is nearly seated in the taper.

PITA.

Snapped some pics... Not sure, but thinking if I can get a porta power or something between the wheel and the disk and put some pressure against the wheel hoping to pull the stud into the flange. Long shot.

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..

Mm that's ugly.
I was going to suggest drilling a hole in the stud and pounding an Allen wrench in the hole to hold the stud. That may be hard to drill through the end of the keyed nut, then a bigger hole in the nut so it will spin around the wrench.

Start masking that wheel off with layers of duct tape. Wrap shim stock in areas where a cutter may nick if you accidentally lose control. Take a chisel and break off the center of the lug nut. Use a carbide burr until you can peel off that junk.

Could also (possibly) grind the tbolt heads at the back of the housing flange. I think then the whole wheel, disk, and axle assemble should pull out.

I really hope I can just get the stud bound up in some way to allow me to back the nut off without going to extreme measures.

Is the rear end an 8 3/4? If not, can you just pull the axle?

I've used a chisel before and split the side of the nut from the front to the back and got it off. The TTII wheels are very tight around the studs. Patience will be the key here...