NHTSA Complaint #11172455 — 2015 SUBARU FORESTER

WHILE COMPLETING A TIRE ROTATION, I PLACED THE SPARE TIRE ON THE HUB AS A PLACEHOLDER WHILE I MOVED ON TO OTHER WHEELS. I HAND TIGHTENED THE LUGNUTS HOLDING THE SPARE ON (NO WRENCH, NO OVER TORQUEING). I LEFT THE DRIVER FRONT JACKED UP SUPPORTED BY A JACK STAND WHILE I COMPLETED THE REST OF THE TIRE ROTATION; THE SPARE WAS NEVER LOWERED TO THE GROUND AND WEIGHTED, IT WAS SIMPLY INSTALLED AS A BACKUP TO MY JACK STAND. WHEN I CAME BACK TO THE DRIVER FRONT TO REMOVE THE SPARE AND INSTALL THE NORMAL WHEEL, 2 OF THE 5 LUGNUTS THAT I HAD HAND TIGHTENED SEIZED. WHEN I ATTEMPTED TO REMOVE THEM AFTER APPLICATION OF PENETRATING OIL, TWO OF THE STUDS SNAPPED RENDERING THE CAR ENTIRELY UNSAFE TO DRIVE. WHEN I WENT AROUND THE CAR WITH A TORQUE WRENCH SET TO THE MANUAL SPECIFIED TORQUE OF 89 FT/LBS A THIRD STUD STRIPPED. I DO NOT KNOW WHAT CAUSED THE STUDS TO SNAP OR STRIP. I DID NOT OVER TORQUE THE LUGNUTS, THEY WERE HAND TIGHTENED LESS THAN 30 MINUTES PRIOR. THERE IS NO REASON FOR HAND TIGHTENED LUGNUTS TO SEIZE ON A WHEEL STUD AND CAUSE THE LUGNUTS TO SNAP OTHER THAN DEFICIENCY OR WEAKNESS OF THE WHEEL STUD. I HAVE NEVER OVER TORQUED THE WHEELS; I ALWAYS USE A TORQUE WRENCH SET TO 89FT/LBS AS SPECIFIED IN THE OWNER'S MANUAL TO TIGHTEN THE LUGNUTS. I DID NOT CROSS THREAD THE LUGNUTS; I RAN THEM DOWN BY HAND TO ENSURE THAT THEY WERE CORRECTLY INSTALLED. MY RESEARCH ON VARIOUS SUBARU ONLINE FORUMS SUGGESTED THAT THE WHEEL STUDS COMMONLY FAIL AND MANY USERS SUGGESTED REPLACING ALL WHEEL STUDS WITH AFTERMARKET HARDENED RACING STUDS RATHER THAN INSTALLING NEW OEM PARTS. WHEN I CONTACTED SUBARU I RECEIVED THE RESPONSE "SUBARU APPRECIATES YOUR TIME IN COMMUNICATING WITH US, HOWEVER WE DO NOT INVESTIGATE EVERY CONCERN THAT IS REPORTED TO US."