After a serious crash, most people assume the tire failed because of something the driver did—hitting debris, underinflating the tires or ignoring maintenance. But many times, those assumptions are wrong.
A tire blowout can result from a manufacturing or design defect: a hidden weakness in the tire that gives out under normal driving conditions. Tread separation, sidewall failure and even the use of aging rubber in new tires can all cause a catastrophic failure, often at high speeds, and without warning.
If the tire is discarded, the opportunity to investigate is lost. And without a clear investigation, the real cause of the crash may never be known.
In this post, we’ll explain:
- What causes a tire blowout—and how to tell if a defect is to blame
- The difference between normal wear and a product defect
- Major recalls and real-world cases
- What to do next if you suspect a tire failure caused a crash
Common Tire Defects That Lead to Blowouts
Blowouts aren’t always random. When they’re caused by defective tires, the failure may have been inevitable. Some of the most common defects that lead to crashes include:
Tread Separation
The outer tread detaches from the inner casing, often at highway speeds. This is a known failure pattern in defective tires and can quickly result in a rollover—especially in SUVs or trucks.
Bead Failures
The bead is the part of the tire that seals against the rim. If it fails, the tire can rapidly lose air, destabilizing the vehicle.
Sidewall Defects
Thin or weak sidewalls can rupture unexpectedly, especially under normal heat and load. Some of these tires are sold with no warning of their limitations.
Aged Tires Sold as New
Tires degrade over time—even unused. Some retailers have been caught selling tires that are years past their safe lifespan. A blowout under these conditions isn’t just dangerous—it may be legally actionable.
These aren’t maintenance issues. They’re design or manufacturing defects, and they often go undetected until after someone is seriously injured or killed.
Tire Blowout Statistics and Real-World Cases
- According to the NHTSA, tire-related crashes cause about 11,000 accidents and over 500 deaths per year.
- The Firestone-Ford recall in the early 2000s linked tread separations to more than 270 deaths, mostly involving rollover crashes in Ford Explorers.
- Goodyear’s G159 tire—used on RVs—was tied to multiple fatal crashes. The company knew of the risks but delayed a recall for years, triggering ongoing lawsuits and federal scrutiny.
Tire recalls happen more often than most people realize. But even tires that were never recalled may be defective.
The Firestone-Ford Tire Blowout Crisis: What Happens When Defects Are Ignored
One of the most infamous tire defect cases in U.S. history involved Firestone tires and Ford Explorer SUVs. In the late 1990s and early 2000s, reports began to surface of high-speed tire tread separations, followed by deadly rollovers. Most of these crashes involved the Ford Explorer, a vehicle with a high center of gravity and a known tendency to roll when destabilized.
Initially, Bridgestone/Firestone recalled 6.5 million tires. But further data showed the risk went beyond the recalled batches. Ford later replaced another 13 million Firestone tires, making it one of the largest tire recalls in history.
The result? More than 200 deaths and 500 injuries in the U.S. were linked to these defective tires.
The case triggered lawsuits across the country, a $41.5 million settlement from Firestone, and ultimately led to the creation of the TREAD Act—federal legislation that strengthened defect reporting requirements and improved consumer safety standards.
This wasn’t a fluke. It was a systemic failure of design, oversight, and accountability. And it left thousands of families asking questions far too late.
Today, tire failures still happen. And just like in the Firestone case, they’re often misattributed to driver error—unless someone knows how to investigate the tire itself.
Why Tire Defect Cases Are Missed—and Why They Matter
The average crash investigation doesn’t include a tire failure analysis. Police reports often cite “driver lost control” or “equipment failure” without further detail. Insurance companies are quick to close these files.
That’s why tire defect cases require an experienced defective car attorney legal team that knows how to investigate properly.
Key evidence includes:
- The failed tire (which must be preserved)
- DOT manufacturing code and tire age
- Crash dynamics and rollover patterns
- Past complaints or recalls for the same model
- Expert analysis from tire engineers and forensic specialists
Without this level of detail, the real cause of the crash is missed, and the responsible manufacturer walks away without accountability.
Why Lucas Law Firm Investigates Tire Blowout Cases
These are complex product liability cases. They require more than a standard personal injury approach.
At Lucas Law Firm, we’re often contacted by crash victims and other attorneys who need help evaluating whether a tire blowout was caused by a defect. Our team knows how to:
- Preserve and examine the tire before it’s destroyed
- Work with national experts in tire failure analysis
- Determine whether a manufacturing or design defect exists
- Litigate against major manufacturers and suppliers
- Secure compensation for medical costs, lost income, and wrongful death
Whether the blowout led to a rollover, ejection or catastrophic injury, our job is to find out what happened—and who is responsible.
When to Contact a Tire Blowout Attorney
If you or a loved one has been involved in a serious crash following a tire blowout, and the cause isn’t fully clear, it’s critical to act fast. Preserving the tire is the first step. From there, a qualified tire blowout attorney can begin building your case.
This is especially important when:
- Injuries were severe, including brain injury, spinal cord injury or fatal
- The blowout seemed to happen out of nowhere
- The tire was relatively new or appeared in good condition
- The crash involved a rollover or vehicle instability
These are red flags, and they often point to a defective tire.
Talk to a Defective Tire Attorney at Lucas Law Firm
Tire failures can lead to devastating injuries. When they’re caused by a defect, the manufacturer should be held accountable.
At Lucas Law Firm, we bring the legal insight and investigative resources necessary to uncover the truth. If a tire defect caused the crash, we’ll find it—and pursue the compensation you and your family deserve.
Contact us today to speak with an experienced tire defect attorney or tire blowout attorney who can guide you through your legal options.
FAQ: Tire Blowout & Defective Tire Claims
What causes a tire blowout?
Tire blowouts may be caused by underinflation, overloading or impact damage—but many are caused by manufacturing or design defects. These include tread separation, bead failure, and aging rubber.
Can I sue if a defective tire caused a crash?
Yes. If the blowout was due to a tire defect, you may have a product liability case. These claims are often brought against the tire manufacturer, distributor, or retailer.
How do I know if a tire was defective?
You won’t know without expert analysis. Preserving the tire after a crash is critical. A product liability firm can coordinate an inspection with engineering experts to determine what went wrong.
What compensation is available in these cases?
Compensation may include past and future medical expenses, lost income, permanent disability, pain and suffering, wrongful death damages, and—if there was clear corporate negligence and conscious disregard for safety —punitive damages.