New 2025 F250 Wheel Explosion- Blowout

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Mas89
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9:16p, 6/29/25
AG
2 weeks old and 960 miles king ranch F250 and we took it on a weekend trip. Returning today, had a blowout on Hwy 59 about 20 miles from home. No prior low tire or light, just a sudden blowout on the L Rear at 70 mph. Took a nearby exit and quickly found a good, large safe driveway to pull into. Put on the spare and made it home safely.

Finger sized hole in the inside of the wheel and corresponding hole in the tire, then a similar sized hole in wheel well and out thru the bed of the truck.
WTH happened? I'm assuming the wheel exploded somehow with metal going thru the tire and then the wheel well. I've Never seen or heard of something like this and what if it would have come into the cab of the truck. What could possibly cause the wheel to explode?

Thoughts?
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Yesterday
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9:27p, 6/29/25
AG
That is wild. I can't imagine what would cause that. Sounds crazy but maybe a bullet went into the tire and ricochet up and out the wheel well?
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Mateo84
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9:30p, 6/29/25
AG
I read this post three times trying to figure out what happened but still have no clue. Glad you guys are okay though!
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Mas89
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In reply to Yesterday • 9:45p, 6/29/25
AG
Yesterday said:
That is wild. I can't imagine what would cause that. Sounds crazy but maybe a bullet went into the tire and ricochet up and out the wheel well?
Not possible on a bullet, whatever went thru the tire and wheel well came from the hole in the Inside of the wheel.
We were in the far left inside lane with no vehicles near us in back. Makes no sense other than the wheel metal failing somehow. I hope to stay at the ford dealership tomorrow long enough for them to take the tire off the wheel. Need to see inside of the wheel and tire.
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Silvy
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9:48p, 6/29/25
AG
That small chunk of wheel would not be able to put a hole through the tire then somehow bounce perfectly back through the hole in the wheel and then have enough force to puncture the wheel well. Whatever it was, it hit the tire first.

Don't forget to disengage the parking brake when you pick your truck up from the shop
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aggiejumper
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9:52p, 6/29/25
AG
Post pic where the debris/projectile penetrated tire tread.

The energy had to be extremely high to go through a tire and the bed. I don't understand how that much speed was generated when pressure was pushing outward in the rim.
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CanyonAg77
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10:01p, 6/29/25
AG
EDIT: Changed my theory. I now think the rim failed and sent a fragment through the tire and fender

That is the craziest tire puncture I have ever seen. Please let us know what caused it.

I'm with the folks who wonder if it was a bullet. Hard to imagine something internal on the wheel having that much energy.
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Ag for Life
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10:07p, 6/29/25
AG
Holy crap, glad y'all are ok! I've never seen or heard of anything like this, that's nuts
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Mas89
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In reply to Silvy • 10:07p, 6/29/25
AG
Silvy said:
That small chunk of wheel would not be able to put a hole through the tire then somehow bounce perfectly back through the hole in the wheel and then have enough force to puncture the wheel well. Whatever it was, it hit the tire first.

Don't forget to disengage the parking brake when you pick your truck up from the shop
A relative was driving but saw nothing in the road and we heard nothing but the blowout. Rear wheel but I guess it is possible something long went into the tire far enough to break a hole in the wheel on the inside and then get thrown out of the hole and thru the wheel well. But nothing was in the bed of the truck and no other damage was seen. All happened an hour before dark today so I'll look thoroughly tomorrow morning.
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Aston 91
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10:11p, 6/29/25
AG
That is bizarre. Many moons ago I worked as a reliability engineer in a chemical plant and did quite a bit of root cause failure analysis on pumps, turbines, compressors etc. We saw some strange failure modes, but nothing like this. I'd guess manufacturing defect led to a fatigue failure of the wheel, but that's just a guess.
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Mas89
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In reply to CanyonAg77 • 10:14p, 6/29/25
AG
CanyonAg77 said:
That is the craziest tire puncture I have ever seen. Please let us know what caused it.

I'm with the folks who wonder if it was a bullet. Hard to imagine something internal on the wheel having that much energy.
I guess a huge spike or nail would contact the wheel after a blowout/ flat tire. As far inside the wheel it is, a bullet would have had to go thru the tire, make a hole in the wheel, and then thru the tire again.

Not sure what to do about fixing the small hole in the wheel well and bedliner. Really don't want to put it in the shop but also don't want mud/ debris getting in the hole in the future. Pita.
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CanyonAg77
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In reply to Mas89 • 10:18p, 6/29/25
AG
Okay, here's my completely uninformed opinion:

Casting flaw on your wheel

70mph, chunk of wheel breaks off

It is flung outward, goes through both the tire (from the inside out) then through the wheel well, then arced up then down and shattered the window of some poor schmuck three cars back
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Mas89
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In reply to CanyonAg77 • 10:24p, 6/29/25
AG
Strangely, the tire never separated from the wheel. It's still mounted so hopefully we will get clues looking inside. Curious what the Ford dealership will say. I'm honestly not sure if it's a wheel failure or road debris. Not much traffic in front or behind at the time.
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CanyonAg77
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In reply to Mas89 • 10:32p, 6/29/25
AG
I'm calling it a rapid deflation, not a blowout. The tire didn't explode, did it? No reason to come off the rim

Again, on reconsideration, your initial thought is what happened. You've got a new set of aluminum wheels. Somewhere in the casting or handling of the wheels (my guess is the casting) a flaw happened in the wheel. Had it been sitting, air pressure may have blown that chunk out toward the center, and it would have hit the parking brake drum and it would have fallen to the ground.

But you were at highway speed, and when it failed, centrifugal force was way higher than the force from air pressure, and the chunk was flung outward through the tire, then the wheel well, then in the air. I'd search your bed, just to see if it landed inside, but I bet it went over the tailgate and onto the highway.
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Mas89
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In reply to Mateo84 • 10:32p, 6/29/25
AG
Thanks. That's the most important part.
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CanyonAg77
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10:38p, 6/29/25
AG
Tire charts say that tire turns 609 revolutions per mile.

70 mph = 1.6667 miles/minute, so 710.5 rpm

Some physics nerd could probably calculate the mass of that hunk of aluminum and figure out how much force was being applied.

I could only figure that the inside of the tire was going 55 feet per second.
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Mateo84
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10:51p, 6/29/25
AG
Could it have been some huge nail or something similar that was driven over, punctured all the way through the tire and was long enough to puncture the wheel, and the force of that interaction plus the tire exploding shot the offending item back out through the wheel well and bed?
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sts7049
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3:56a, 6/30/25
AG
wow. never seen anything like that before.

i find it really hard to believe it was anything on the ground being run over, just the likelihood of that seems so remote to hit it so perfectly to puncture only the rim and wheel well and not damage anything else.

i think the casting flaw projectile theory holds the most sense, but even then that seems like a rather odd type of hole failure. i'd have thought you would see a crack type failure if that were the case.
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fixer
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5:50a, 6/30/25
Debris from the brake rotor maybe?

Totally wild.
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highpriorityag
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6:31a, 6/30/25
Hope you bought tire and wheel

looks spendy

I wonder what else is faulty on that truck
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dodger02
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6:59a, 6/30/25
AG
Nm
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Buck Compton
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7:20a, 6/30/25
AG
In my opinion, you hit something solid that was long enough to go through tire and break the wheel. Look at how the metal failed.

That wasn't just a wheel failure to send it through the tire and bed with lining. Whatever you ran over got sent through the bed as well
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Buck Compton
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In reply to highpriorityag • 7:21a, 6/30/25
AG
highpriorityag said:
Hope you bought tire and wheel

looks spendy

I wonder what else is faulty on that truck
Faulty or hit something?

And why wouldn't he buy wheel and tire? He had to…
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Mas89
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7:28a, 6/30/25
AG
Just looked good and only found one clue. King Ranch wheel is made in China? lol
So would the projectile go thru the double wall wheel well if it was steel instead of aluminum? If this was an Expedition, I assume it would have gone into the third row left passenger seat and could have hit a passenger.
If a front tire, would have gone into the engine compartment.
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Mas89
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In reply to Buck Compton • 7:34a, 6/30/25
AG
Buck Compton said:
In my opinion, you hit something solid that was long enough to go through tire and break the wheel. Look at how the metal failed.

That wasn't just a wheel failure to send it through the tire and bed with lining. Whatever you ran over got sent through the bed as well
Makes sense. 60D x 6" nail or long 3/8 bolt the head would have stayed outside the tire with the inside part puncturing the wheel, then getting thrown thru the wheel well possibly.
The Only thing I've ruled out completely is a bullet.
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Buck Compton
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In reply to Mas89 • 7:44a, 6/30/25
AG
Mas89 said:
Buck Compton said:
In my opinion, you hit something solid that was long enough to go through tire and break the wheel. Look at how the metal failed.

That wasn't just a wheel failure to send it through the tire and bed with lining. Whatever you ran over got sent through the bed as well
Makes sense. 60D x 6" nail or long 3/8 bolt the head would have stayed outside the tire with the inside part puncturing the wheel, then getting thrown thru the wheel well possibly.
The Only thing I've ruled out completely is a bullet.
Yeah, that's what I'm thinking. One of my buddies had something similar happen to his Ram 1500 when we're in college. Long piece of rebar hit his front wheel then got flung through his floorboard behind his driver seat. He heard a bang, had a flat tire, stopped, and when he opened his back door there was about 9 inches of rebar still sticking out of the floorboard. Had gone through several layers of metal and plastic.

Only thing that he didn't have was the punctured wheel.
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classicdoug
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In reply to Mas89 • 7:47a, 6/30/25
AG
Mas89 said:
Buck Compton said:
In my opinion, you hit something solid that was long enough to go through tire and break the wheel. Look at how the metal failed.

That wasn't just a wheel failure to send it through the tire and bed with lining. Whatever you ran over got sent through the bed as well
Makes sense. 60D x 6" nail or long 3/8 bolt the head would have stayed outside the tire with the inside part puncturing the wheel, then getting thrown thru the wheel well possibly.
The Only thing I've ruled out completely is a bullet.
I agree. The metal around both the wheel hole and bed hole is bent outward.

Steel and/or aluminum would have done about the same thing as far as the wheel well goes. How you fix the bed is going to be up to you. Welding Ford's aluminum sucks. An insurance company would most likely pay to replace the inner and outer bedside. If it was mine, I would fix the hole and not cut up a brand new truck.
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Mas89
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In reply to classicdoug • 7:53a, 6/30/25
AG
Thanks Doug.

How would you fix the hole? This is what I want to do and not have it in the shop forever or tear the bed apart.
Could it be patched or welded possibly?
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mm98
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In reply to Aston 91 • 8:21a, 6/30/25
AG
Aston 91 said:
That is bizarre. Many moons ago I worked as a reliability engineer in a chemical plant and did quite a bit of root cause failure analysis on pumps, turbines, compressors etc. We saw some strange failure modes, but nothing like this. I'd guess manufacturing defect led to a fatigue failure of the wheel, but that's just a guess.


You think maybe it was a weld repair on the wheel that got broke loose and flung up through the tire and the bed ?

I know that's a huge reach
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classicdoug
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In reply to Mas89 • 8:49a, 6/30/25
AG
Mas89 said:
Thanks Doug.

How would you fix the hole? This is what I want to do and not have it in the shop forever or tear the bed apart.
Could it be patched or welded possibly?
If this was my truck, I would hammer the aluminum around the hole flat first. Next I would cut another piece of aluminum slightly larger than the hole, maybe quarter size. In the body shop world we have two part epoxy called panel bond which is used to glue roofs, quarter panels, etc. on to cars. I would panel bond the patch inside of the wheel well covering the hole. Then once that is dry, I would take a brush and fill the small spot on the top side with bedliner and then texture it to match the rest of the bed. I think you could make it pretty unnoticeable.
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Silvy
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In reply to classicdoug • 8:58a, 6/30/25
AG
Which beer cans work the best for aluminum patches?
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TexasRebel
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9:15a, 6/30/25
AG
Rock stuck in the rotor venting?

Wild that something would get through the wheel and tire with enough force yet to go through the bodywork.

At 600 rpm and estimating a 13" rotor, the Relative Centrifugal Force is about 60 Gs.
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Mas89
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In reply to TexasRebel • 9:26a, 6/30/25
AG
Don't think so. Definitely an exit hole in the wheel. And dual exit holes going thru the wheel well.
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TexasRebel
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9:37a, 6/30/25
AG
This happened under motion, correct?

The hole in the wheel being an "exit" hole almost defies physics. Aluminum breaks in funny ways.

Any damage to the rotor?
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sts7049
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In reply to Buck Compton • 9:54a, 6/30/25
AG
Buck Compton said:
In my opinion, you hit something solid that was long enough to go through tire and break the wheel. Look at how the metal failed.

That wasn't just a wheel failure to send it through the tire and bed with lining. Whatever you ran over got sent through the bed as well
this just doesn't make sense to me though. as unlikely as this was in the first place, how perfect would it have to have been to have debris puncture through the tire and rim, and then neatly get flung up so precisely to poke only a tiny hole in the bed going upward without hitting anything else? i don't buy that. is the tire even punctured on the outside??

the bed hole is so small, it almost has to be from the piece of rim material ejecting out.
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