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I used to rotate my own tires on my 2003 Tundra and now and then noticed thread damage and some recalcitrant nuts going on and off, usually after they had loosened half a turn or so.
The problem I was having was rust on the exposed threads. I started shooting the exposed threads wax-based corrosion inhibitor. It helped, but most of the damage was already done. It was really aggravating when they didn't cooperate, but I never replaced the studs (lazy).
Then a tire shop broke a stud off while installing new front tires. Fortunately they didn't have a new stud on hand, if they had they would probably have just changed it and charged me a few bucks. They parked the truck outside while I went to the Toyota dealer and bought 12 new studs and nuts and had them change all of them. When it was time for new rear tires I showed up with 12 new studs and nuts for the rear.
They aren't that expensive.
I always shot the new studs with wax-based corrosion inhibitor and never had another problem.
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