I am reporting a recurring, catastrophic suspension defect in my 2023 BMW i4 eDrive40 that results in life-threatening rear tire failure. Despite adhering to all maintenance schedules, the vehicle's rear axle geometry fails to maintain stability, leading to extreme, accelerated inner-tread wear while the center and outer tread remains healthy. Timeline of Events: Initial Incident 5/4/2025 (21,493 miles): Suffered a sudden rear tire blowout while driving due to the inner tire wall wearing down to the metal cords. The dealer (BMW of Fort Lauderdale) performed an alignment and replaced the tires on my expense. Recurring Failure 3/6/2026 (35,200 miles): Less than 14,000 miles after the dealer-certified alignment, the new rear tires have reached a catastrophic state. The inner shoulders are completely bald (2.7mm inner vs 4.8mm outer), exposing the safety protector and creating an imminent risk of a second high-speed blowout. Manufacturer Response: The authorized dealer inspected the vehicle on 3/9/26 and stated the "alignment is within factory specifications," yet they refused to address why a vehicle "in spec" is destroying safety-critical components in under 14k miles. This indicates either a fundamental design flaw in the suspension components (e.g., bushings or control arms unable to support EV weight/torque) or defective factory alignment parameters provided by BMW for this specific model. Safety Hazard & Lack of Warning: This defect is a "silent killer." The failure occurs on the innermost edge of the tire, which is physically obscured by the vehicle’s body and cannot be seen during a standard walk-around. Because this EV has no regular service intervals (like oil changes), there is no professional opportunity to inspect the inner tires. A driver has no way to predict or diagnose this before a sudden, high-speed blowout occurs. BMW claims the car is "within spec," which indicates a fundamental design flaw that makes the vehicle un-roadworthy and dangerous
NHTSA ODI 11722997