2016 FORD FLEX — Problems, Recalls & Safety Data

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.

The contact owns a 2016 Ford Flex. The contact received notification of NHTSA Campaign Number: 25V695000 (Back Over Prevention); however, the part to do the recall repair was not yet available. The contact stated that while in reverse, the rear-view camera image was blurry. No warning light was illuminated. The local dealer was not contacted. The vehicle was not diagnosed or repaired. The manufacturer was not made aware of the failure. The failure mileage was approximately 55,000.

The contact owns a 2016 Ford Flex. The contact received notification of NHTSA Campaign Number: 25V695000 (BACK OVER PREVENTION); however, the part to do the recall repair was not yet available. The contact stated that the rearview camera displayed a distorted image while the vehicle was in reverse(R), and the screen glitched. The contact stated that the failure obstructed the driver's visibility, which prevented the driver from safely operating the vehicle. The local dealer was contacted. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was not made aware of the issue. The failure mileage was unknown.

The contact owns a 2016 Ford Flex. The contact stated that while driving at an undisclosed speed, the brake pedal was depressed; however, the vehicle failed to stop as intended. No warning lights were illuminated. The contact stated that the failure had frightened him because a pedestrian was nearly struck by the vehicle. In addition, the contact stated that when the vehicle was started, the RPM was elevated and then lowered. The vehicle was not diagnosed or repaired by an independent mechanic or dealer. The manufacturer was not made aware of the failure. The failure mileage was 35,000.

Hands free phone and sync will not connect. Not able to enter the correct date. 05/2023.