As per my Ford dealer, this is a known issue, but Ford will not warranty the lug nuts as they consider this normal wear & tear. Funny that I’ve worked on my own vehicles and had them serviced by dealers for over 42 years and never had this happen. I was told by the service manager that Ford told them to use a 21.5 MM socket on the lugs that were swollen to remove them, as opposed to the 21 MM that is the correct, original OEM size, which is the size lug wrench that was supplied by Ford with the vehicle. That’s fine if Ford doesn’t want to warranty the lugs, but they should at least warn owners before they are stuck with a flat tire and no way to change it. So, I’ve now got my new 1 piece solid steel lug nuts on the truck. They were pricey, but fit PERFECTLY on my OEM lug wrench and look great! These are some beefy lug nuts, as you would expect on a truck of this caliber.
Don’t get me wrong, I love my Raptor, and I’ve never owned a vehicle that I enjoyed driving more. A little heads up on a known issue would go a long way with how consumers feel about how honest their vehicle manufacturer is. Honesty goes a long way with most of us.