Awww.
Just tried the Tire Size Calculator here and a warning came up that said you shouldn't increase the tire diameter any more than 3% over the stock tire or you risk brake failure.
The Diameter Difference with the LT215/85R16 tire is 12.74%
Oh well...
~ Joe in NY
The reason they state that is for liability reasons.
Anything more than 3% will throw your speedometer off [You'd be amazed how many people have installed huge tires on their car/truck, only to come back with a ticket saying its our fault.]
Secondly, is that a lot of people with 4x4's, try to cheap out and change only two tires. When you have something like huge mud terrains or swampers, the difference in worn out tread can actually equal 3% or more, causing all sorts of drivetrain issues. All of our suppliers require four tires, of the exact same brand and model to be installed on any 4x4. Most people don't realize, two tires of different brand, but same size aren't actually identical in diameter. You can get a 33x10.5R15 say, That can range anywhere from 31.5-33.5" tall [In extreme cases]. Same thing with performance tires. Nitto 555R's are a great tire, I've personally used them.. but their 275's were narrower than my BFG 265's.
The 3% rule is also because a lot of people put big tires and rims on their vehicles, without ever upgrading their braking system. We get people all the time with jacked up SUV's who wonder why it takes a lot longer to stop, going from a stock 28-29" tire, to a 35" tire. It doesn't seem like THAT much heavier [it is lifting it, I assure you
], but it's all rotating mass. The vehicle weight only goes up by a bit, but it directly effects braking exponentially, which creates significantly more heat, hence the possibility of brake failure. I'd say 1/10 [if that] people I see who put on significantly bigger rims or tires upgrade their braking system. We also have a few vehicles per month come in, where the older style ABS sensors trigger due to increased diameter. The newer style TPMS sensors don't matter on diameter at all.
Some manufacturers will also void a warranty on the vehicle if you go out of 3%, regardless if you change all four or not. I know we had an issue with an Acura MDX, customer came in, wanted bigger tires, Acura has a note in our system to contact the dealer because they do not want anything larger or smaller installed. Called the dealer, they basically said any mechanical failures are the responsibility of the client, Acura does not condone tire size changes with their AWD vehicles.
Also anything over 3% will change the ride and handling of the vehicle. Too tall of a sidewall and the vehicle will feel 'squishy' compared to stock, and it will generally made handling a lot less responsive. Too short of a sidewall, and I hope you know a good back surgeon. The vehicle will respond quicker but at a massive sacrifice to ride comfort.
One of the problems we also see a lot, is putting putting super wide tires on their cars/trucks, and then not being able to drive through rain or snow. In wet weather, a narrower tire will do better as it has more pounds per square inch of force pushing down and makes it harder to hydroplane. In dry weather a wider tire generally causes more traction under heavy acceleration. In 'thick' mud, a wider tire is generally better. On ice, with a good ice tire you also want a wider tire as it has more surface area and a bigger contact patch. Most often, it's not worth the loss in snow traction to get a little bit better ice traction, and this doesn't apply to 'general snow tires' Only specialty ice tires. So it's best to find a good all around balance in size.
All of that being said. Too heavy of a tire can/will cook your brakes during a hard stop from highway speeds. Stock braking systems are rarely designed to handle an excessive increase in tire weight, which can cause your brakes to absorb more heat than they are designed for, causing brake failure. It can also cause an excessive strain on your transmission and engine if your vehicle does not have the power to handle it. Putting significantly bigger tires on something with a weak transmission is never advised.Basically, it's not 'unsafe' as long as you realize your braking and handling could be adversely effected and you stay within reason. It's there so the guy running 37" Super Swamper's on stock tiny brakes can't come back and complain when his brakes are a smoking pile from repeated hard stops from highway speeds, or wonder why his transmission has no first gear anything, trying to push 37's up a hill from a stop every day.
Sorry for the incredibly long winded response haha.. I've dealt with this question a billion times, and I've spoke to some of our suppliers about it in detail.. So I figured I'd share what they have to say.