Procedure to replace damaged or broken wheel studs on a 2015 Kia Forte, requiring removal of the wheel hub assembly to press out old studs and install new ones.

Warnings

Tools required

Parts

• Wheel stud(s) × 1 — Use OEM specification
• Axle nut (if applicable) × 1 — Use new, do not reuse
• Cotter pin (if equipped) × 1 — Use new

Preparation

1. Park vehicle on level ground and apply parking brake
2. Place wheel chocks behind rear wheels
3. Loosen wheel lug nuts 1/4 turn while vehicle is on ground
4. Raise vehicle with floor jack and support securely on jack stands at manufacturer jacking points
5. Remove wheel completely

Procedure

1. 1

   Remove brake caliper and bracket
   Remove the two caliper mounting bolts and lift the caliper assembly off the rotor. Support the caliper with wire or a bungee cord to avoid stressing the brake hose. Do not let it hang by the brake line. Remove the caliper bracket bolts and remove the bracket from the knuckle.
2. 2

   Remove brake rotor
   Remove the rotor retaining screw if present. If the rotor is stuck, spray penetrating oil around the hub contact area and tap gently with a rubber mallet to break it free. Slide the rotor off the hub.
3. 3

   Remove axle nut (if accessing hub assembly)
   If the hub assembly must be removed to access the stud, have an assistant apply the brakes or use a pry bar to prevent hub rotation. Remove the axle nut using a 30mm or 32mm socket and breaker bar. This nut is torqued to 250 Nm and will require significant force to remove. Discard the old nut as a new one must be used.
   Torque spec

   Axle Nut250 Nm (184 lb-ft)
4. 4

   Disconnect lower ball joint and tie rod end
   Remove the cotter pin and castle nut from the lower ball joint. Use a ball joint separator or pickle fork to separate the ball joint from the knuckle. Remove the tie rod end nut and separate the tie rod from the knuckle using the same method. Be careful not to damage the boots.
5. 5

   Remove hub assembly bolts
   Locate the hub assembly mounting bolts on the rear of the knuckle (typically 3-4 bolts). Remove these bolts completely. Carefully pull the hub assembly away from the knuckle, being mindful of the ABS sensor wire if equipped.
   Torque spec

   Mounting Bolts26 Nm (19 lb-ft)
6. 6

   Remove damaged wheel stud
   Place the hub assembly on a secure work surface or in a hydraulic press. Using a press or large C-clamp with appropriate support blocks, press the damaged stud out from the back side of the hub flange. The stud should slide out once sufficient pressure is applied. If using a hammer method, support the hub properly and drive the stud out carefully to avoid bearing damage.
7. 7

   Clean stud bore
   Use a wire brush to thoroughly clean the stud bore in the hub flange, removing any rust, debris, or metal shavings. Ensure the bore is completely clean to allow proper seating of the new stud.
8. 8

   Install new wheel stud
   Insert the new wheel stud into the bore from the back side of the hub flange. The serrated shoulder must face the wheel mounting surface. Using a hydraulic press or draw the stud into place using a washer and lug nut, tightening gradually until the stud shoulder is fully seated against the hub flange. Ensure the stud is straight and fully seated.
9. 9

   Reinstall hub assembly to knuckle
   Position the hub assembly back into the knuckle, aligning the bolt holes and ensuring the ABS sensor wire is properly routed. Install the hub mounting bolts and tighten in a cross pattern to the specified torque.
   Torque spec

   Mounting Bolts26 Nm (19 lb-ft)
10. 10

    Reconnect suspension components
    Reconnect the lower ball joint to the knuckle and install the castle nut, tightening to specification. Install a new cotter pin. Reconnect the tie rod end and tighten the nut to specification, installing a new cotter pin if equipped.
11. 11

    Install new axle nut
    Install the new axle nut onto the axle shaft. Have an assistant apply the brakes or use a pry bar to prevent rotation. Torque the axle nut to specification. Stake the nut or install a new cotter pin as specified by the manufacturer.
    Torque spec

    Axle Nut250 Nm (184 lb-ft)
12. 12

    Reinstall brake rotor and caliper
    Slide the brake rotor back onto the hub and install the retaining screw if equipped. Position the caliper bracket and tighten bolts to specification. Install the caliper assembly over the rotor and tighten the caliper mounting bolts to specification.
13. 13

    Install wheel and torque lug nuts
    Mount the wheel onto the hub, ensuring it seats properly on all studs including the new one. Thread all lug nuts by hand to prevent cross-threading. Lower the vehicle until the tire just contacts the ground to prevent rotation. Torque the lug nuts in a star pattern to specification.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)

Reassembly

1. Ensure all suspension fasteners are torqued to specification and cotter pins are properly installed
2. Verify the new wheel stud is fully seated and flush with the other studs
3. Double-check that brake caliper bolts are properly tightened

Verification

• Spin the wheel by hand to ensure it rotates freely without binding or unusual noise
• Verify all lug nuts are torqued to 140 Nm in a star pattern
• Test drive vehicle at low speed and verify no vibration or unusual sounds from the wheel area
• Re-check lug nut torque after 50-100 km of driving

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