I have a 91 420sel that I had tires put on.The lugs were put on so tight that only 2 would come out without snapping.Is there a way to take the hub off so that I can remove the tire without cutting the wheels off?

There is a tool that is used to drill the flange off the remaining piece to get the wheel off. I imagine the tool is available at www.baumtools.com or you might check with your local MB specialists to see if they have one and want to do it for you. It might be cheaper than buying the tool.

__________________
Steve Brotherton
Continental Imports
Gainesville FL
Bosch Master, ASE Master, L1
33 years MB technician

You can purchase a 1/2 or 9/16 Cobalt drill bit to drill through the outer shoulder, or the tapered head. The secret to drilling any material is watching for the long curly shards. If you are not getting the curly strands of metal than the bit is spinning too fast, slow it down until you see the curls consistently and stay with that speed. The Milwaukee 1/2 variable speed drill is my tool of choice; I can turn the bit slow enough to cut through that hardened bolt. Plan on 10 to 15 minutes for each broken bolt and try to stay as centered as possible when drilling.

When drilling metal keep in mind "if you hear the bit squealing you have no metal peeling!"

A dab of lubricant on the drill bit may help.

__________________
95 E320 Cabriolet, 159K

We run into this quite often. The tool from Technic Tools takes to long. We purchased a 1" hollow mill (1/2 HSS - dolfa 5-540-060) from Nate's Industrial Tools, Inc. in Torrance, CA (310) 325-6262. This fits over the broken bolt and just cuts the outside. Snap-On supplied us with a tool to hold the mill from the inside that allows us to connect the mill onto the drill. The new Snap-on rep. cannot find the part/part no. for this tool again. The mill takes off some of the metal from the rim away. We put a modified washer with the new lug bolt. This gets pressed in and stays there forever. This job you can do in 10 minutes.
Good luck;
Jean

I neglected to state that when you drill the bolt you will get to a point where the "tapered head" has little or no material connecting it to the threaded shank. At this point it will simply break off. Once the wheel is removed you should be able to remove the threaded section providing they were not stripped or seized by the 40+ rata-tat-tats to the lug from the impact gun.

Let us know how things went!

I went to the local welding shop and got some bits to try.One is called a locksmith bit used for drilling safes and the other is cobalt.From what they tell me is the locksmith bit will drill out a broken easy out.
I'll let you know how it worked.Thanks for the help.

These bolds are not very hard. You don't need a special bit.
It took me 15 minutes.
The most important thing is to have a low rev drill, 300 revs max.
And if you start with a small size bit ,
DO NOT BREAK IT !!!!!