When I took the wheels off of my 99 Mustang GT, one of the wheel studs fell out. Looking closer, you can see that the splines are gone. The splines grip the wheel stud and keep it from rotating inside the hub while the lug nuts are torqued. The easiest and best fix for this problem is to simply replace the wheel hub. 94-04 Mustang front wheel hub replacement is a simple and painless process.
Removing the Caliper
Before the wheel hub can come off, the caliper and rotor must be removed.
Two bolts that hold the caliper bracket to the wheel assembly. These are the larger of the four bolts behind the caliper, with 15mm heads. The caliper stays attached to the bracket.
When those bolts are removed, the caliper will slide off of the rotor in one shot. There’s no need to retract the pistons or remove the pads, as long as you don’t press the brake pedal during this procedure.
Once the caliper is out of the way, the rotor slides right off.
Removing the Wheel Bearing Dust Cap
There is a dust cap covering the wheel bearing and axle nut. If you’ve worked with trailer bearings, the principal is the same. It needs to be gently pried off with a couple of screwdrivers or similar. Note that you have to be extremely gentle. It punctures very easily. Getting these off in one piece is probably the worst part of the job.
Removing the Old Wheel Hub
A big breaker bar goes a long way on the next part. With the dust cap off, you can reach the axle nut. Bust it loose. I’ll note here that you’re not supposed to use an impact on this nut, although I suspect that’s primarily for tightening and not loosening.
Once the nut is off, the wheel hub slides right off after it.
Lubricate and Install the New Bearing
Before sliding the new hub on, be sure to clean the axle shaft with brake cleaner or similar. It also needs some grease. Generic wheel bearing grease seems to work fine. Once it’s all ready, the new hub slides right on.
Once the new hub is on, a new axle nut can be installed. Torque it down to 250lb-ft with a big wrench, and the hub is reinstalled. Lastly, gently tap the dust cap back on. Don’t forget to reinstall the rotors and calipers. The larger caliper bracket bolts torque to 85lb-ft, while the smaller ones are 25lb-ft if you removed them.