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Your factory custom wheels are designed to use a specific lug nut, most of these lugnuts today include a built in washer that contacts the wheel surface. Your maintenance of re-torqueing the lugnuts after 100 miles following wheel removal is exceptional, and textbook...(some wheel manufacturers recommend this after 50 miles:) I am a long time wheel person through many years of performance wheel applications. My guess would be that a previous owner had installed custom wheels, and removed them at time of selling your Santa Fe...they mistakenly left the aftermarket lug nuts on your car...and these lug nuts do not contact your wheel where they should be to remain tightened...Don't buy new lug nuts unless you can test this possibility first...All salvage yards would have inventory of factory wheels and lugnuts...Also shop on line...confirm the size of your wheel studs...ie 12 mm rht..."right hand thread" and search for someone selling factory wheels...many auto parts stores will confirm your wheel stud thread size any offer replacement sets too. Hope this helps.
There are about 5 different patterns for those insert type (which were improved/discontinued due to the insert wearing out) only available through a dealership, if they can still get one. Most dealerships (some tire shops) mechanics will have a set to use for repairs. Once you can get the key (or the lugs removed) I would suggest buying an aftermarket set of security lugs and throw those away. The type for years 1996-2001 (I believe) become hard to get proper lug torque once they become worn and almost impossible to get back off after some corrosion of the wheel stud.
It sounds like you have some loose lugnuts. Luckily, Your car should have all the tools to fix this right next to the spare tire. To see for sure, jack up that side of the car, following the instructions on stickers near the spare tire or in the owners manual. You will need to jack up that corner of the car, and use the lugnut wrench to tighten those nuts as tight as you can get them with that little thing. If this was the problem, you need to then drive the car to the nearest tire repair store and have them tighten those down for you. If you have a torque wrench, tighten them to 85 ft/lbs.
Get a four way lug wrench that and loosen, but do not remove, all the lugnuts on the wheel that has the flat.Next, jack up the car by lifting it up from the side underneath the doors on the pinchweld.Then remove the lugnuts.Install the spare after removing the flat.Tighten the lugnuts till they are snug on the wheel,then lower the jack .Then torque the lugnuts tight after the car is back on the ground, and you're ready to go down to the tire shop to get the flat fixed.Hope I could help!!!!
The lugs are generally pressed into the rotor. They have a fluted shank which prevents them from turning when you torque the lugnuts. If you are going to do this job yourself, they can be driven out with a punch. The new replacement can be drawn into position with the lugnut, but you might need to utilize some spacers and washers to do this.
I've performed this operation before with the rotor still on the vehicle.
I hope this helps... Good luck!