disc swap issues - wheel studs

Alright, so I'm doing the disc swap in my '69... I go to press the hub/disc assembly together and the stud splines won't engage in the hub. You can drop them in and pull them out. Most of the holes in the hubs are around .010" larger than the stud's spline OD. I went and looked at the old studs and all of them have a noticeable flare at the end of the splines, that could have enlarged the holes slightly as they were pressed out.

WTF do I do now? Is there an otherwise identical stud with slightly larger splines I could use after enlarging the holes? Do I have to get a different set of hubs and hope those holes aren't enlarged too?

Any direction would be appreciated.

Thanks,
Tony

 

Alright... I found some similar studs that might work.

The knurl diameter is .667" which might be perfect for a tight fit. My holes were measuring .635" to .645"
They are .094" longer overall than the spec'd Dorman 610-106's.
The shoulder is .781" (.031" shorter than the Dorman studs), but a mock-up measurement of the hub/rotor shows that .750 would allow for full engagement on both the rotor and the hubs.

If I'm interpreting and comparing the numbers correctly, they *should* work. Only concern is that these are a "287" head and the spec studs are a "106" head. What does that mean and does it matter that it's different?

 

Alright, well these studs seem to be working. The splines are only cut partway down the shoulder, so the splines only have engagement about 40% of the way though the hub, but the splines are slightly engaged in the holes on the brake rotor. One of them will hold the hub/rotor assembly together while shaking it up and down (over a soft surface of course) so I guess they're good to go if you have the same hole enlargement problem as me.

Balkamp 6411579 is the part number, available at Napa. Applications include 2006-2008 Jeep Commander and 1994-1999 Dodge 1500 trucks.