03 GCV Can't remove lug nuts
 

I am having a problem with my 2003 Grand Caravan. The shop where I have my oil changed and my tires rotated cannot remove the 20 lug nuts on the van without breaking at least 1 of the wheel studs in the proccess of rotating the tires. They tell me that the lug nut is stuck and the only way to remove it is break the wheel stud. When I ask why this is happening there awanser is it's a common problem with some GCV's.

I think there just over torquing the lug nuts when they put them back on. Can anyone help me with this problem

Most places use an impact gun for removal and installation. As a guess, instead of the recommended 100 ft.lbs, the impact gun tightens them to at least 200 ft.lbs.
As to your question, it sometimes works if you heat the nut enough to expand it off of the stud. An impact gun doesn't impose a side load on the stud so it's probably the best bet for avoiding a broken stud.
Just make them use either a torque wrench or torque stick rated at 100 ft.lbs when they do the reinstallation.

Thanks for the info. I will tell them not to over torque the lug nuts at my next tire rotation

could be the wheels haven't been taken off for years and have rusted on.

I use heat when this problem occurs i bought one of these and it ROCKS. especially when lug nuts on aluminum rims are stuck.
http://www.theinductor.com/index.php?m=50&s=24

The wheels on the van are steel with plastic wheel covers and crome lug nuts in front of them. I think heating them is out of the question.

Rust is not the case here, I get the tires rotated every 6000 miles. I have been using the same shop for this work, and they sold me the van 2,1/2 years ago. in that time they have replaced 4 or 5 lug nuts and studs.

last month when I replaced the front brake pads, I broke 2 studs taking off the drivers side wheel.

I just had the tires rotated two days ago, and the shop broke a rear stud in the proceess trying to remove the lug nut. they didn't even get a lug nut that matched the size of the other ones on the van.

I checked the owners manual last night and found the torque spec for the lug nuts to be 95 FT-LBS. I am gonig to the shop today with the correct replacement lug nut, and have them re-seat all the lug nuts to the proper torque. then in 6000 miles we will see if all lug nuts on the van can be removed without breaking studs.

I would look for a new service center.I had the same problem a few years back. Every time i took it to a certain garage on Detroit rd I could not get the lugs off. The mechanics are just too lazy to turn down the air pressure when putting the lugs back on. If you ever get a flat you are screwed. Your car would most lily have to be towed to a garage.

wow, that's a $hitty repair shop. you NEVER crank lug nuts on with an air gun (unless you have Accutorq tools http://www.torqstik.com/ )

I have these and they are dead on. in the years I've been using them, I never had lug nuts come loose nor have them hard to get off even with the factory lug wrench.

Oh and like we had any clue you are over anal about rotating tires. cuz from your problem that's EXACTLY what happens from lack of rotation. if you don't find a better quality repair shop, you'd be a fool.

I had 3 weeks ago the same problem, when i wanted to check the break pads and discs on the rear axcle of my Grand Caravan.
It ended up with breaking the stud, cause the nut got stuck on the stud, when i tried to open it.

I believe also in the theorie, that the nut was overtighten. Bought last year some allseason tires and never touched them. Probably the dealer cranked them down like hell.

Removal of the lug nut covers
 

I'm having difficulty just removing the covers. The mechanic that my wife brought the van to said there is a special tool. I find that hard to believe because, what if I need to fix a flat tire. It can't be that difficult.

Any insight on this?

Welcome to DF
Anytime you have the tires rotated or repaired, always watch the tech and be sure they are using a torque wrench.