Need to replace broken lug bolt

Front (4 Wheel Drive) To Remove:

1. Raise and support the vehicle
2. Remove or disconnect the following:
   • Tire and wheel assembly
   • Rotor (See: Disc Brake Rotor)
   • Wheel speed sensor and brake hose mounting bracket bolt from the steering knuckle
   • Electrical connection for the wheel speed sensor
   • Front drive halfshaft assembly (See: Halfshaft)
   • Hub and bearing assembly mounting bolts 4WD front hub
     
     
   • Hub and bearing assembly

To Install:

1. Clean all corrosion or contaminates from the steering knuckle bore and the hub and bearing assembly
2. Lubricate the steering knuckle bore with wheel bearing grease or the equivalent
3. Install or connect the following:
   • Hub and bearing assembly
   • Hub and bearing assembly mounting bolts and tighten the hub to knuckle bolts; Torque to: 133 ft. lbs. (180 Nm)
   • Front drive halfshaft assembly (See: Halfshaft)
   • Electrical connection for the wheel speed sensor
   • Wheel speed sensor and brake hose mounting bracket bolt to the steering knuckle and tighten the bolt; Torque to: 106 inch. lbs. (12 Nm)
   • Rotor (See: Disc Brake Rotor
   • Tire and wheel assembly
   Wheel lug nut tightening sequence
   
   
4. Torque the lug nuts to specification
5. Test drive the vehicle to confirm the repairs

often what happens is bolt pattern same like 6 lugs but the the bolts themselves are far apart from each otheri looked up 04 4x4 tocoma bolt pattern is 717x225mm). Big Hub. Bolt pattern: 6x139.7 (6x5.5). Offset: 2 to 22 mm.. it could work the rea test is to try one wheel and see if it fits do front one because of the 4x4 hub in front i would need to know what type chevy?

Remove wheel, brake caliper and rotor. Give the broken lug a good shot with a decent weight hammer and drive it out of the hub flange. Put new stud into hole, place a stack of washers on it and place the lug nut on backwards (flat side in)
Use oil on the threads to prevent binding, tighten lug 'till stud is seated, replace everything you removed.

I'll try to help you. If you are having trouble with 3 out of 5 studs on one wheel you may want to go to an autoparts store or Salvage yard to look at the whole hub. Usually a press is used to remove the bolts so you would be taking off the hub anyway. When you pay for 3 bolts and labor you may be better off in a Salvage yard or parts place for a different hub. The rear hub on front wheel drive cars is like a trailer axle. Much simpler to remove mounting bolts and press in new bolt. But if rear has differential(rear wheel drive) it has an axle shaft. Would be easier to grind and drill out broken stud on car. You can draw new bolt into place by placing bolt through a socket and use the wheel nut to draw the bolt into the hub.

here is procedure

Section 04-01: Suspension and Wheel Hubs, Front 1996 Taurus, Sable Workshop Manual
REMOVAL AND INSTALLATION Wheel Hub Bolt Removal

1. Raise vehicle on hoist.
   

1. Remove wheel and tire assembly. Refer to Section 04-04 .
   

1. Remove disc brake caliper (2B120), and front disc brake rotor (1125). Refer to Section 06-03 .
   

Brake Shoe and Lining Removal

1. Remove brake master cylinder filler cap (2162). Check fluid level in brake master cylinder reservoir (2K478). Remove brake fluid until brake master cylinder reservoir is half full. Discard removed fluid.
   

1. Raise vehicle on hoist. Refer to Section 00-02 .
   

1. Remove wheel and tire assembly from front disc brake rotor mounting face. Use care to avoid damage or interference with disc brake caliper (2B120), front disc brake rotor shield (2K004) or front wheel knuckle (3K185).
   

1. Remove rear brake pin retainers (2N386). ( I think it is a T 40 torx bit you need)
   

1. NOTE: It is not necessary to disconnect hydraulic connections.
   
   Lift disc brake caliper from front disc brake caliper anchor plate (2B292) and front disc brake rotor (1125). Do not pry directly against metal caliper piston or damage will occur.
   

1. Position disc brake caliper out of the way and support with wire to avoid damaging the disc brake caliper and front brake hose (2078).
   

1. Remove outer brake shoe and lining (2001) assembly from front disc brake caliper anchor plate.
   

1. Remove inner brake shoe and lining assembly.
   

1. Position lug bolt (1107) to clear front wheel knuckle (3K185).
   

1. Remove lug bolt from wheel hub (1104).
   
   
   
   

Installation

1. Install lug bolt into wheel hub.
   

1. Using a lug nut (1012), seat wheel hub bolt into wheel hub.
   

1. Install front disc brake rotor and disc brake caliper. Refer to Section 06-03 .
   

1. Install wheel and tire assembly. Tighten lug nut to 115-142Nm (85-104 lb-ft).
   

Below is a link to the front rotor and all components on a 4WD Jeep Cherokee.

http://www.chiltonlibrary.com/content/images/8674/images/86749g36.pdf

4-Wheel Drive

1. Loosen the lug nuts on the front wheels.
   
2. Raise and support the vehicle safely.
   
3. Remove the front wheels.
   
4. Remove the calipers, but don't disconnect the brake lines. Suspend the calipers out of the way.
   
5. Remove the rotor.
   
6. Installation is the reverse of removal. Tighten wheel lug nuts to 75 ft. lbs. (101 Nm).
   

Best of luck!
Greg

Only if there is an Acsess Hole Directly Behind the STUD'S PUNCH THE Broken SHORT one OUT But there May Not Be Enough ROOM FOR the NEW LONG STUD to go in between the HUB & Rotor Check this FIRST If you see GOOD CLEARANCE TO GET The new STUD in Then just Drive the old one out , and Use A LARGER than Stud Nut Or Washers to Pull New Stud Threw some Before Putting Wheel on. Then Put Wheel on And Tighten Wheel , Retorque after a Few Hundred Miles.

It appears you need to kick it off. Siezed up on the hub.

there is a large nut that holds that hub on. Remove the cotter pin and the cap from the bolt... remove the bolt and the hub comes off.

Robert

The rotor and hub assembly are held together by the studs,you must first remove the 4-wheel drive hub assembly,then the wheel bearing nuts,and pull the hub and rotor off as a unit. Next lay it(back down) on a piece of wood, using a drift punch drive the studs out. Turn it over ,lay it(face down) on a block of wood, line the new stud splines up with the grooves in the hub and drive them in with the punch and reassemble. A set of dentist style picks will be helpful with the clip in the 4wd hub and a 4 lug 4wd nut wrench will be needed.