NHTSA Complaint #10140028 — 1999 FORD EXPEDITION

I WORK AT A TIRE STORE AND HAVE SEEN ON NUMEROUS OCCASIONS, LUG STUDS SNAPPING WITH TORQUE WRENCH USE OF 100 PSI. ON FORD AND LINCOLN TRUCKS AND SUV'S. IT IS ONLY HAPPENING TO THE ONES WITH 10 MM LUG STUDS. THE METAL ON THE INSIDE OF THE STUD HAS VARYING SHADES OF GREY IN IT. IT LOOKS LIKE THE METAL IS NOT THE SAME ALL THE WAY THROUGH. ONCE THE STUD SNAPS, THE NUT CAN BE SCREWED OFF BY HAND AND IS NOT CROSS THREADED. WHEN TRYING TO TORQUE THEM, THE NUT KEEPS TURNING UNTIL THE STUD SNAPS. WE HAVE DONE THIS USING DIFFERENT IMPACT GUNS AND TORQUE WRENCHES ON A MINIMUM OF 15 VEHICLES WITH ANY WHERE FROM 1 TO 8 STUDS SNAPPING. THE CUSTOMERS THINK WE ARE BREAKING THEM FROM INCOMPETENCE. FORD RECALLED STUDS FROM 1997 TO 1998. I HAVE SEEN IT ON 1999 AND 2000 MODELS WITH 10 MM STUDS. WHEN I SEND THEM TO THE DEALER ON THE LATER MODELS, THEY ARE TOLD IT IS NOT COVERED. *JB