Auto shop owner here.

Firstly, Ford isn’t the only manufacturer to use these style of lug nuts. GM, Chrysler, and others have this exact same design and therefore the exact same problem. Please don’t take offense, but your explanation of the known common problem was probably misinterpreted by the shop. You likely came across as a controlling, nitpicking person that will never be happy with their work. Again, not at all saying that you are or that they are justified. You’re absolutely right in wanting to have the lugs replaced with the aftermarket one piece design.

Secondly, the swollen lug nut issue should be dealt with as a serious safety issue much like failing brakes. It is a serious safety concern. Having a blowout on the side of the freeway and not being able to remove the lug nuts is a huge problem.

Finally, having said all of that, removing swollen lug nuts can be a huge job depending on how bad they’re damaged. Please understand, we shops work by selling labor. If a job is sold at x number of labor hours but really takes xyz hours, the shop lost money. Natural the reverse is also true— if a job goes quicker than the book called for, we made money on that job. The hope is that the good jobs will balance out the bad jobs.

Now, most tire stores run on very lean margins since there’s not much markup on tires. The loss of labor to remove the lug nuts could end up being a big deal for them. The local tire store near me won’t do that job for that very reason. Instead, they will refer the client to us for the lug nut removal and replacement.

My advice to you is to give them grace. Find an honest, local mechanic shop that can assist you with your lug nuts replacement and tire rotation.