Just bought replacement wheel studs for '92 240 front. I'm now at work, and have access to a Bench Grinder.
How much do I grind off? Just a flat on the Outside Diameter of the Head?

Help, so I don't have to do this at home with a Dremel.

Had the same problem, I actually just took one corner off rather than try to grind it flat. You don't have to take off much, maybe 3/16" from one corner. Then tap them past the ABS ring with that corner facing it. Grind at about a 45 deg. angle.

It would help to grind a little then test, as I did, but if you can't do that, just take as much as you dare off of one corner and do the rest at home with a dremel.

Why do you need to grind anything off? Are the replacements a different length from the originals? If so it should only matter if you are using acorn nuts, or the new ones are so much longer that they interfere with the wheel cover.

If they do indeed need to be shortened, what about pressing out one of the old ones, and making the new ones the same length? Or are you trying to get a different length for some reaon?

Nothing to do with length.

Clearance on Head/shank to clear ABS sensor ring during assembly.