Montero wheel stud broken

Captive rotors can go to hell

That wheel above? It’s the left-front wheel on my Mitsubishi Montero. The hub is a six-bolt setup, but at the moment it’s been downgraded to five bolts. Why? Because well testing the fit on my new wheel and tire combo, a wheel stud snapped. That bit of rifled metal sheared right off and left me scratching my head for how I’m going to replace it.

After a quick scan of YouTube, it seems that swapping out wheel studs is actually quite easy. You remove the wheel. Clear the brake caliper with a bolts or two, and then slide the rotor out of the way after removing two more bolts. That would be how I planned on clearing the way for a new wheel stud, until I learned that my Montero uses captive rotors.

Montero wheel stud broken

Someone please stop the bleeding…

For those unaware, a captive rotor is one that can’t simply be removed with the hub in place. That’s because it’s part of the hub essentially. I now need to remove the dust cap, snap ring, shims, drive flange, spring washer, lock nut, and all of the various bits of hardware holding those pieces in place. Once I do that, I can get to the dust shield and rotor.

And then I’m still not done. The hub is still attached to the brake disc at this point. I’ve just removed it from the front axle. So that means more bolts and likely a bit of prying as well. It’s a good idea to change the wheel bearings at this point, if they haven’t been done yet.

This was supposed to take ten minutes.

Once you’ve got the rotor free, it’s easy work to remove the old wheel stud and get the new one inserted. But now the battle is merely half over. Everything that was removed …yadda yadda, installation is the reverse of disassembly.

*deep breath*

I think I can handle this one myself. It’s just quite a bit more work than I expected. And to that, I say, captive rotors can fuck right the hell off… though that will take them quite a few steps to get there.

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22 responses to “Captive rotors can go to hell”

  1. neight428 Avatar
    neight428

    If removing a wheel gets you one critical failure like that, just think what’s lurking in that hub!

    1. Jeff Glucker Avatar
      Jeff Glucker

      Nah, snapped wheel stud isn’t indicative of what’s going on in the hub. Just shit luck with that stud.

      1. 0A5599 Avatar
        0A5599

        Remember, lefty loosey, righty tighty.

        Tire store guys remember this even when you drive a Mopar/Packard/whatever with LHT on the driver’s side, and you have that tidbit written onto the service order. Voice of experience speaking.

        1. Batshitbox Avatar
          Batshitbox

          Hee-hee! I remember when my ’63 Scout had 5-lug hubs in the rear with RHT on both sides, but 4-lug hubs in the front with LHT on one side.
          Now I think of it, I can’t remember if the 5-lug hubs I eventually fitted to the front had LHT on one side or not.

      2. neight428 Avatar
        neight428

        Not indicative, no, just so many more points of potential failure along the way. Best of luck!

  2. crank_case Avatar
    crank_case

    My last 10 minute job took six months..

    1. danleym Avatar
      danleym

      I’m two months into a timing belt right now…. admittedly a 1 to 2 day job, but nonetheless I’m way past my budgeted time on it…

  3. anonymic Avatar
    anonymic

    I did a brake job on a Dodge D50 once and went through the same ordeal. The only solace I can afford is just be glad you’re not doing rotors on a wire wheel MGB that hasn’t been disassembled in 30 years. Getting the dust cap off can take as long as replacing your wheel stud.

  4. discontinuuity Avatar
    discontinuuity

    I wonder if there’s a way to hammer out the wheel stud and put a new one in from the back? I’m having trouble visualizing this setup.

    If you have to take apart everything you might as well replace the wheel bearing while you’re in there.

    1. Jeff Glucker Avatar
      Jeff Glucker

      There’s no room in the back because the rotor can’t easily come off. That’s the way I was hoping to do it, knocking the broken stud out and drawing in the new stud with some washers.

      Yep, everyone recommends wheel bearing if you’re replacing a stud because you’re already in there.

      1. 0A5599 Avatar
        0A5599

        Sometimes there is an access hole or slot in the backing plate. The broken lug would need to be rotated to the exact position. Then push it out and push the new one in.

      2. Vairship Avatar
        Vairship

        Clearly you need to use bread!

    2. Fuhrman16 Avatar
      Fuhrman16

      This is what the captured hub on my Mitsubishi designed Hyundai looked like. I imagine the one on Jeff’s Montero is similar. Basically the only way to remove the rotor is to completely disassemble the hub, which I believe requires a special tool to do.
      https://uploads.disquscdn.com/images/76e8b4226886cc60ebb6bb818470b54457abbe9659cb6ebe00871fefcde944df.jpg

      1. Jeff Glucker Avatar
        Jeff Glucker

        Read a description in a forum and it was pretty straightforward with no special tools. But I also have my Haynes sitting next to me and I’m leafing through that as well.

  5. Lokki Avatar
    Lokki

    And so it begins….

    The saddest words ere spoke by man are,
    While you’re in there…..

    You mentioned in your first article that:
    Up front, the steering needs some attention. There’s a very minor wobble in the steering wheel. I need to get the front end off the ground and give each wheel a nice shake to see what might be going on there.

    Quite seriously, as long as the front end is ripped apart, you might consider doing ball joints, and almost definitely replacing the wheel bearings which are no doubt older than your mother, and which likely haven’t been repacked with fresh grease since Bill Clinton was President. Further, if one wheel stud has snapped take a good look at the rest. Think how much it would piss you off to break off another stud next time you go to rotate the tires…..

  6. Fuhrman16 Avatar
    Fuhrman16

    Dang Jeff, I feel for ya. Went through something similar with my Lemons car. Wound up just replacing the entire hub assembly with a spare I bought from another team. It was the way easier route in the amount of time I had.

  7. Scoutdude Avatar
    Scoutdude

    Back in the day we would clean, inspect and repack the wheel bearings on a regular basis, and maybe replace the seals on a regular basis. I’d only replace them if the inspection reveals that it is needed.

  8. Tank Avatar
    Tank

    Years ago I worked for a Honda dealer and I remember the 1995 Accord (only year I think) had “press on” aka Captive rotors. They even had to be cut on the vehicle. PITA

    1. Smaglik Avatar
      Smaglik

      1994 also. I got to bear that brake job expense as a college student several times.

    2. Smaglik Avatar
      Smaglik

      1994 also. I got to bear that brake job expense as a college student several times.

    3. Scoutdude Avatar
      Scoutdude

      Honda had captive rotors for ages, starting with the 600, though on those the bearing was not a part of the deal to remove the assembly. You just had to pull the axle nut and slide it off. starting with the Civic the hub was pressed in the bearing in the knuckle.

      1. Tank Avatar
        Tank

        ah, I only worked there in the early 00s. those were all but a memory by then. We did have one in the showroom however