93 Mazda Protege broken lug.

[pred8tr]

Hey folks. I have a 93 Mazda Protege, DOHC 1.8l manual. I have a broken front lug. I removed the steering knuckle and bought two from the junk yard only to find they didn't fit. One was due to ball joint pin size. The other due to rotor size. Argghh... I called the dealer and they want ~$150 to press my existing assembly apart and install a new lug bolt and press it back together. That seems a bit expensive to me. A new knuckle is over $300.00. What other options are open to me?

Thanks,

Pred8tr

[mannydingo]

That's crazy. This is a perfect example of why these boards are such a blessing. The same thing happened with my 94 Protege. I bought the lug at the dealership. It cost like 4 bucks. I then took it to the place that usually changes my CV joints with the ones they rebuild. Yes, I've taken driveaxles out, etc. It's cheap enough to warrant not working or getting myself dirty so I ge it done instead. I came back to them one day and said the last time they took the lug nut off that they put it back on twisted so the lug broke. The guy put the new lug in within 20 minutes. I was there for another job so he didn't charge anything. Go to any place that works on suspensions with the new lug in hand and ask them how much to replace it. If it sounds too high then go elsewhere. This is not major car surgery. I think the rears are supposed to be worse. One of the two(front or back) is harder than the other.

[ALIEN3T]

i had my mustang years ago done all 10 both front drums done fo rlike 20 bucks!

there was a article in import tuner awhiel back when they changed some brakes on their subie, they changed the lugs, used washers and a breaker bar and an old lug and tighten it down tilll it pressed itself in! and they hammerd out the old ones (since they werent goign to eb used anymore)

if not it should cost much a few dollars!

[mannydingo]

i had my mustang years ago done all 10 both front drums done fo rlike 20 bucks!

there was a article in import tuner awhiel back when they changed some brakes on their subie, they changed the lugs, used washers and a breaker bar and an old lug and tighten it down tilll it pressed itself in! and they hammerd out the old ones (since they werent goign to eb used anymore)

if not it should cost much a few dollars!

I got a headache reading that. I'm going to rewrite it for you. It will not be perfect grammar either but more clear:

I had my Mustang's done years ago. I had all 10 on the front done for, like, 20 bucks.

There was an article on Import Tuner done a while back when they changed some on their subie. They changed the lugs, used washers and a breaker bar and an old lug. They tightened it down 'till it pressed itself in! They then hammered out the old ones(since they weren't going to be used anymore).

[txbajabill]

I have the same problem ... seems a stud bolt will not clear the knuckle and the hub assembly MUST be removed to get the broken stud out. Then the hub & bearing assembly must be pressed back into the knuckle assembly. Same 93 protege. I'm hoping for a simpler fix, but expecting to have to press out the hub & bearing assembly before being able to replace the broken stud.

[bgibb68]

the washers is how i replaced one on my dad's car....i didn't even pull the knuckle...i was able to get the old one out and squeezed in the new one....and then used washers and and impact wrench and 'pulled' the lug through

[txbajabill]

I can't squeeze it out, so I surely can't squeeze it back in. Pulling to seat it once it's in won't present a problem. I'm talking about 1/2" of knuckle assembly in the way of hammering out the broken stud.

The parts store gave me two styles of studs. One had a plain round head (old style) and one had a semi round head w/ a flat edge on one side (to squeeze around the knuckle assembly). I'm assuming they figured out the problem and corrected it in later models of protege. Unfortunately, all my OEM studs have round heads and not the later.

I seem to have the worst luck with Murphy.

[mannydingo]

the washers is how i replaced one on my dad's car....i didn't even pull the knuckle...i was able to get the old one out and squeezed in the new one....and then used washers and and impact wrench and 'pulled' the lug through

Are you talking about your '02 'cause these guys have 90-94 Proteges. Well, the first guy posted the problem 2 years ago so he may have had it replaced already. If it's a 90-94, maybe you can be more specific.

[91Protege]

Lol Just cut it out, and maybe you can fit the one with the cut out in. Lisle Tools makes a stud installer. Its pritty sweet.
http://us.st12.yimg.com/us.st.yimg.com/I/rodi_2044_780124228

[txbajabill]

I got the new stud in and seated it without removing the steering knuckle and pressing the hub out. Thank you, Mr. Dremel!

http://www.mazdas247.com/forum/showthread.php?t=123735071