Broken/cross-threaded wheel bolts happen. A combination of over torque and weekly swaps took their toll on mine.

Cross threaded bolt:

See pic one

Follow these steps to replace the front wheel bolts on an '02-'03 WRX (part #28055AA002). I'm not sure if the same steps apply to earlier or later models.

Tools:
- 12mm socket or wrench
- 17mm socket (1/2" drive recommended)
- 19mm socket (to remove wheel)
- 3" extension
- Hammer

Steps:
1. Remove the wheel(s) (19mm).

2. Unbolt the brake line holder at the strut (12mm).

see pic 2

3. Remove the top bolt from the caliper (17mm).

See pic 3

4. Lossen the bottom bolt on the caliper (17mm).

5. Using the bottom as a hinge pull the top of the caliper away from the rotor.

See pic 4

6. Turn the hub so the broken bolt is lined up with the gap created when you moved the caliper and hammer the bolt through (takes a couple good whacks). Repeat for each bad bolt.

7. With the hole lined up with the gap insert the replacement bolt from behind the rotor.

See pic 5

8. Use an open ended lug, or a stock lug with a washer, on the bolt to pull it completely through (the bolt head should be flush with the rotor).

see pic 6

9. Push the caliper back into its place on the rotor and tighten the two caliper bolts (80 Nm (8.2 kgf-m, 59 ft-lb)).

10. Reattach the brake line holder.

11. Put the wheel(s) back on (90 Nm (9. I kgf-m, 65.7 ff-lb)) and test drive.

12. Check the torque on the lugs to make sure they didn't seat further after diving.

I recommend replacing the stock lugs with ones that have more thread material. I'm not sure if more thread = distributed load, but after replacing with open ended lugs I have not had any problems.

Good luck.

- Ray