[Gunter]

Originally Posted by xxultramistersi

I was going to change the wheels on my 1989 911 coupe and when I went to put the new wheels on, one nut would not torque properly. After taking the wheel off and inspecting it a little bit a buddy of mine noticed that the threads on the bolt(part the nut attaches too) had a flat spot that carved a new thread in the lug nut. We tried the nuts that weren't damaged, and they would not go on either(we didn't force it, as to save them). Could we have damaged the actual bolt without pneumatic tools? The torque wrench was set to 90 lbs and it wasn't even clicking. The car was in the shop a few weeks ago and they undoubtedly took off the wheels with an air wrench, so that's on possible cause.

Another question, how easy is it to remove and replace one of the bolts that the lug nuts attach too? This is a pain in the ass, but I am glad we caught it before a track day rolls around.

Alu nuts are softer than the stud, so, a thread-chaser might fix the stud.
If that's not satisfactory, install a new stud like uwanna says.

The thread was most likely damaged not by removing the nut with an air gun but by installing the nut.
Some of these jockeys don't start the thread by hand but insert the nut into the gun and then just aim for the hole without any lube.

I'd talk to the manager about this and expect them to pay for the new stud.
And, of course, never go back there for more "service".

BTW: I would remove each lug nut and apply the lube recommended by Porsche and torque with the correct 95-96 ft-lbs.