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I had this same problem with a Ford F150 I purchased. The local Ford dealer had a box of the "master" keys but none of them would fit. While I was waiting around, one of the Service Techs overheard the conversation and when the Service Manager walked away the guy came over and told me they see this problem all the time. He said there is no need for me to pay them to get them off. He said they just use an air chisel. Just push it into the outer edge of the lug and they will spin right off.
Well I went home, got out my air chisel and sure enough, they spun right off! Just be careful so you do not slip and run the chisel accross the face of your rim!
It is actually very easy to get them off.
Does work, have done it in the past but its VERY risky. One slip and your wheels are gouged.
Think I'd have a tire shop remove one and send it to the lock manufacturer, and handle it from there. Sound's like the dealer is willing to work with you on cost's. I've been using Mcgard product's for year's, and some how ended up having two set's with the same code. I alway's get a spare key to hang on the basement wall, along with the code card.
I've been there too, and it's precisely why I don't recommend anyone buy locking lugnuts. It's just not worth the hassle if you lose the key. The wheel studs in passenger cars aren't tough enough to warrant the risk of abuse, and the easier you make it to recover without a key the easier they are to steal in the first place. So your wheels get stolen, maybe your oil pan gets scratched up, big deal. Insurance will likely cover that. You're on your own, however, with this kind of stuff.
Buy a cheap 6 point socket that is slight smaller than the lug nut. POUND it on the locking lug. Remove with breaker bar. Repeat on other locking lug nuts. Hardest part of this method is getting the old lug nut out of the socket. Clamp socket in vise, pound lug nut out with a big drift punch.
That's exactly how mine came off.
I replaced them with regular lug nuts.
Apparently the locking ones don't stop the thieves much, just the owner when the
Factory torque spec on a lug nut for a Vette is 100 ft lbs. If you are cranking them down as tight as you can you are adding nothing - other than the opportunity to warp your brake rotors.
I love you back yard engineers, lets see.... the rotor sits flat on the hub flange{inside the "hat"} what exacly would make it sit at an angle or how would you pull one side down and another up?