Every time someone (including Hyundai dealer service) removes any of my
2002 Elantra front tires, a wheel nut gets damaged needing to break and
reinstall new stud and wheel nut. From my many years as car owner this
problem has never happened this often. Is anyone else having this problem?
Besides care by not mounting a thread and starting the wheel nut by-hand,
is this a material quality issue? I would appreciate any/all comment(s).

 

I've had this problem only a handful of times in ten years. Someone is
either overtightening the nut or crossthreading it, thus damaging the
threads. If someone did this once with all wheels, then you now have 16
studs in marginal condition. Of course, if you've used aftermarket
replacement studs, there could be a problem with their material quality.