The meat and potatoes:

A wheel stud from a Mazda3 is compatible with rear hub from S40.

The back story:

Had summer tires/wheels changed to winter setup about a month ago. I've been going to the same tire shop for over 15+ years - they handle ALL my tires and wheel needs... rotations, flats, wheel changes etc. They are a professional shop who understands torque and wheel nuts (read: my nuts were NOT put on too tight).

As many of you are probably aware Volvo uses a capped wheel nut/lug. These type of nuts can swell (bigger nuts). If/when they do swell it becomes very difficult to remove the wheel nut, which is what happened a month ago with the wheel change. Unfortunately, one of the studs snapped off in the process.

I immediately contacted the local Volovo dealer who told me I HAD TO PURCHASE A NEW REAR HUB ASSEMBLY. Cost = $340.00 CDN. The tire shop suggested I try and find a used hub from a junker. Three weeks later I still had no luck finding a used rear hub from an '05 S40. Then I remembered Volvo and Mazda's collaboration on the S40 and the Mazda3.

I contacted the local Mazda dealer and asked for a stud for a current model Mazda3. "No problem" they said "we have several in stock". Cost = under $6.00 CDN.

The bottom line:
I purchased a stud from Mazda. The tire shop removed the rear hub from my 2005 S-40, knocked out the damaged stud and replaced it with the Mazda stud. Cost = under $15.00 CDN.

 

Thanks. Definitely the best deal of the year.

 

Thanks a ton RayMck. I snapped two of them on my wifes 2004.5 S40 T5 in one shot yesterday morning. I came here looking for an answer and you have it. I had to wait one day as the Mazda dealership had to order me the studs.Even with the overnight shipping I still saved $175 USD as the Volvo dealership wanted $200 for the complete hub assembly. The parts tech even seemed surprised I could not order just thestuds.