Cut the rear axels... just do it.

[SilverStealth]

I had some time today so I decided to trim my rear axels so I don't have to worry about non-Expedition center caps.

I followed the advice provided by the members here. I slowed the sawzall speed way down... it cut much better going at a slow speed. And spritzed it with WD40 every now and then, which had the added bonus of keeping the metal dust in check.

I didn't have a nut to thread onto the shaft which definitely would have helped my cut be straighter, but it worked out fine anyway. Total time for actually cutting was about 15 minutes per axel. I took my time with it and kept the speed slow. I also wrapped the lugs with tape and braced my saw against them.

I used a 6" blade with 14 TPI. After I was done cutting, I cleaned things up with a metal file so no one accidentally gets cut down the road. Anyway, here's some pics. Just do it. It's too easy not to do it.

 

[SilverStealth]

Also wanted to add.... F U Ford and your crappy swollen lug nuts!! Our Expy was built in Oct. 2024 and I live in a very temperate climate... 7 months old and the lugs were swollen. Garbage product, Ford... do better.

 

[BigOleFordFan]

Good job, congrats !

ps: Gotta luv those Dewalt cordless tools ! I have that same sawzall, as well as 13 of their other tools & will probably never use anything else....

F U Ford and your crappy swollen lug nuts!! Our Expy was built in Oct. 2024 and I live in a very temperate climate... 7 months old and the lugs were swollen. Garbage product, Ford... do better.

Yea I ditched my OEM nuts a while back after noticing that 7 of the 24 had lost their flimsy-assed stamped metal outer shells/caps.. They were replaced with solid steel Gorilla nuts (take that any way you want to.. )

 

[kryichek]

Any chance this messes up the axle balance?

 

[SilverStealth]

Any chance this messes up the axle balance?

I sure hope not, but considering my cut wasn't exact even... it's possible. I'll let you know after I drive it a while.

 

[Boosted]

Any chance this messes up the axle balance?

I highly doubt any imbalance issue. Our tires are turning at ~600 rotations per mile so even if you were going 100mph you might see 1200 rpm at a ~1/2" radius. Running over a dog shit would cause more vibration.

 

[bb37]

In addition, any imbalance created by cutting the axle shaft is close to the center of rotation which would tend to make the imbalance unnoticeable.

 

[Dark Z]

Great Idea, I think a Milwaukee M12 bandsaw might be more suitable for the location of this cut.

 

[BigOleFordFan]

Great Idea, I think a Milwaukee M12 bandsaw might be more suitable for the location of this cut.

That tool may work too, but from what I have seen here & elsewhere, most folks use a reciprocating saw, otherwise known as a "sawz-all"

 

[LanceExp2025]

Hi Silver Stealth:

No, I am NOT aware of the "Swollen Lug Nuts" Ford Expy PROBLEM!

First I have heard of this. Could you educate me on what is happening here, with these lug nuts? I have just purchased a 2024 Expy MAX Limited with the 22" Polished Aluminum Wheels to replace a 2012 Expy EL Limited that we have owned since new. My six (6) 'exposed' lug nuts appear to be the normal chrome plated lug nuts. Are these "Swollen Lug Nuts" on my New 2024 Expy w/ my 22" Aluminum wheels? If so and if my lug nuts are junk, what are the solid steel lug nuts called, what thread size are they, where do I get them and how much do they cost? (guess I need 24 pcs.) Thanks for your help and knowledge here, Lance

 

[texsn95]

Same question as above, we just got a 22 and the rear wheels have only been off once for a pair of tires, but if this is a systemic issue, then I'll have some real lugnuts waiting.

 

[SilverStealth]

Hi Silver Stealth:

No, I am NOT aware of the "Swollen Lug Nuts" Ford Expy PROBLEM!

First I have heard of this. Could you educate me on what is happening here, with these lug nuts? I have just purchased a 2024 Expy MAX Limited with the 22" Polished Aluminum Wheels to replace a 2012 Expy EL Limited that we have owned since new. My six (6) 'exposed' lug nuts appear to be the normal chrome plated lug nuts. Are these "Swollen Lug Nuts" on my New 2024 Expy w/ my 22" Aluminum wheels? If so and if my lug nuts are junk, what are the solid steel lug nuts called, what thread size are they, where do I get them and how much do they cost? (guess I need 24 pcs.) Thanks for your help and knowledge here, Lance

And @texn95,

Here are some of the many threads covering swollen lug nuts:

Swollen lug nuts. Replace them NOW

Hello friends, I just realize this has been discussed before, but I had the unfortunate roadside flat, and it took an hour to get the six Lugnuts off because I thought the Ford supplied lug nut wrench with the jack was defective . It was not. Long story short all the fourth Jens come out of...

www.expeditionforum.com

https://www.expeditionforum.com/threads/swollen-lug-nuts-recommended-replacement.52023/

I took other members' advice and bought the Gorilla lugs.

 

[Ugh_J]

Ford Swollen Lug Nut Removal & Replacement (complete Guide)

In this video, I discuss the issue with the Ford two piece Lugnuts design that eventually becomes a swollen lug nut. I also go over the parts and tools neces...

www.youtube.com

 

[East-TN]

I had some time today so I decided to trim my rear axels so I don't have to worry about non-Expedition center caps.

I followed the advice provided by the members here. I slowed the sawzall speed way down... it cut much better going at a slow speed. And spritzed it with WD40 every now and then, which had the added bonus of keeping the metal dust in check.

I didn't have a nut to thread onto the shaft which definitely would have helped my cut be straighter, but it worked out fine anyway. Total time for actually cutting was about 15 minutes per axel. I took my time with it and kept the speed slow. I also wrapped the lugs with tape and braced my saw against them.

I used a 6" blade with 14 TPI. After I was done cutting, I cleaned things up with a metal file so no one accidentally gets cut down the road. Anyway, here's some pics. Just do it. It's too easy not to do it.

How much of the end did you cut off? Was this accomplished for future fitment of F-150 wheels?

 

[Gary Waugh]

The swollen lug nuts are the chrome plated nuts, basically the metal underneath the chrome corrodes and creates an oxide, which is contained underneath the chrome, so you can’t see the corrosion, but the chrome gets pushed away from the surface of the nut by the corrosion, and when you try to fit a socket, it won’t go on as the nut has become too large. Once the nuts are off, you can remove the chrome and then wire brush the corrosion off, but the nuts won’t look very pretty and will just corrode again. I forget which make I purchased but there are several vendors selling wheel nuts, but the expedition has used 2 different thread sizes on the wheel nuts over the last 20 years, so make sure you buy the core thugs!! I believe the diameter is the same, but they used 2 different thread pitches.. hope that helps.

 

[Gary Waugh]

The swollen lug nuts are the chrome plated nuts, basically the metal underneath the chrome corrodes and creates an oxide, which is contained underneath the chrome, so you can’t see the corrosion, but the chrome gets pushed away from the surface of the nut by the corrosion, and when you try to fit a socket, it won’t go on as the nut has become too large. Once the nuts are off, you can remove the chrome and then wire brush the corrosion off, but the nuts won’t look very pretty and will just corrode again. I forget which make I purchased but there are several vendors selling wheel nuts, but the expedition has used 2 different thread sizes on the wheel nuts over the last 20 years, so make sure you buy the correct nuts! I believe the diameter is the same, but they used 2 different thread pitches.. hope that helps.

 

[texsn95]

Thanks Stealth, found these for a pretty good price. We're making a road trip from Houston to Ruidoso in 2 months, so the last thing I want to have to do is screw around with this issue. https://www.ebay.com/itm/166284324874?

 

[GixxerJasen]

How much of the end did you cut off? Was this accomplished for future fitment of F-150 wheels?

Yes, it's for F150 wheels. You don't have to cut off much, but the dust covers won't go on without the cut. No idea why they made them so long in the first place.

 

[Gary Waugh]

Jixxerjasen, that’s a nice looking expedition, I believe we have spoken occasionally on two wheeled Texans web site also!! Do you still participate on TWT?

 

[SilverStealth]

How much of the end did you cut off? Was this accomplished for future fitment of F-150 wheels?

I aimed to cut between 3 to 4 threads... around 3/8inch or so. I did it because I'm changing out wheels, and I didn't want to worry about it.