NHTSA Complaint #11717780 — 2016 FORD FLEX

I am reporting repeated structural failures involving Cooper Zeon RS3‑G1 tires (size 255/45R20) installed on my 2016 Ford Flex AWD. These failures include steel belt exposure, rubber separation, and premature carcass breakdown, all occurring at under 30,000 km (~18,600 miles). This represents catastrophic structural failure well before even half of the expected service life for comparable performance all‑season tires. The failures occurred across two separate sets of RS3‑G1 tires under normal driving conditions. The tires were properly inflated, aligned, rotated, and used seasonally. This is not treadwear, misalignment, or maintenance‑related — it is structural degradation of the tire body. Structural separation with exposed belts presents a serious safety hazard, including the potential for sudden air loss or blowout at highway speeds. Risk is further elevated on AWD vehicles due to driveline sensitivity to uneven rolling diameters or abrupt tire failure. I contacted Cooper/Goodyear beginning 03 NOV 2025, providing detailed written documentation of the failures. The only responses received were generic treadwear/warranty templates that did not address the structural issues reported. I explicitly requested written‑only communication and provided a clear response window plus a 2‑week grace period. No substantive written response was ever provided. All defective tires remain mounted on wheels and stored indoors. I have a complete photographic evidence package and a preserved written correspondence record, available upon request.