1. Safety First:
* Don't drive the vehicle: Driving on a wheel with a broken stud is extremely dangerous. The wheel could come off completely.
* Find a safe, level location: Work on a stable surface, ideally with the vehicle on a jack stands (never just a jack).
2. Options for Repair:
* Replace the Stud: This is the best and safest solution. It requires removing the wheel, drilling out the broken stud (if necessary), and installing a new stud. This is fairly straightforward but needs the right tools. You'll need:
* Wheel wrench: To remove the wheel.
* Jack and jack stands: To safely lift and support the vehicle.
* Hammer and punch (or drift punch): To remove the broken stud (if it's still partially in place). A good quality punch is vital to avoid damaging the knuckle.
* Drill and drill bits: The right size to drill out the remaining broken stud if needed. Start with a smaller bit and work your way up.
* New wheel stud: Get the correct replacement stud from a parts store (AutoZone, Advance Auto Parts, etc.). Specify your vehicle's year, make, and model to ensure you get the right one.
* Socket and wrench: To install the new stud. You might need a special socket to fit the stud.
* Torque wrench: Essential to tighten the new stud to the proper specification; tightening too much will strip the threads or break the stud; too little and the wheel won't be secure.
* Penetrating oil: May help if the broken stud is difficult to remove.
* Use a Stud Extractor: If the broken stud is difficult to remove by simply drilling it out, you might need a stud extractor tool. This is a specialized tool that screws into the broken stud to help remove it.
* Replace the Knuckle (Least Desirable): In rare cases, if the knuckle (the part of the suspension the stud is attached to) is damaged beyond repair, you may have to replace the entire knuckle. This is a much more involved and expensive repair that should only be considered if other options are not feasible.
3. Steps to Replace a Wheel Stud (if feasible):
1. Remove the Wheel: Safely jack up the vehicle, secure it with jack stands, and remove the wheel.
2. Remove the Broken Stud: If the broken stud is sticking out, carefully use a punch and hammer to tap it out. If it's broken below the surface, you'll need to drill it out carefully.
3. Clean the Hole: Make sure the hole is clean and free of debris.
4. Install the New Stud: Carefully install the new stud, making sure it's seated correctly. Use the right socket to avoid damaging the stud.
5. Tighten the Stud: Tighten the new stud to the manufacturer's specified torque. This is crucial for safety. Consult your vehicle's repair manual or a reliable online source for the correct torque specification.
6. Reinstall the Wheel: Mount the wheel and tighten the lug nuts. Again, use the correct torque.
7. Lower the Vehicle: Carefully lower the vehicle and check for proper wheel alignment and clearance.
Important Considerations:
* Repair Manual: A repair manual for your specific 1997 Geo Tracker is invaluable for this job. It will provide detailed instructions and torque specifications.
* Professional Help: If you're not comfortable performing this repair yourself, take your vehicle to a qualified mechanic. A broken wheel stud is a serious safety issue.
This process can be challenging, especially removing a broken stud. If you're unsure about any step, seek professional help to avoid further damage or injury. Safety should always be your top priority.
