Tire wear questions

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My zx2 Escort has slightly worn down the wear bars on the inside of the front right tire. the drivers side looks fine. about a year ago I put new outer tie rods on it and had it aligned. They did not report any problems during the alignment. I have about 35-40K miles on this set, which in my experience is GREAT for a little 14" tire. It drives straight, with the wheel centered and doesn't pull. Tire pressure is 35psi @ all corners. I would say I have about 35% service life out of the other 3 and 25-30% out of the front right, not a large difference. I rotate them every 10k miles, I'm thinking in terms of revs per mile on a 14" 5k might be better.
The car is a 99' and has 203,xxx miles.
Should I look for something or just rotate them now and call it a day?
Thanks,
Dusty
 
I am now doing 5k rotations which is great for tires but at some point I think I'm going to have to replace lug nuts. Also, it's not easy to get the right torque without a torque wrench. Last time the nuts were too tight. Before that they weren't tight enough.

You should get 1 new tire that's the same circumference as the one on the other side. I guess it would be easiest just to get the same brand and model.
 
I have BF Goodridge Touring tires on it at at 4 corners. They are all the same circumference. I'm thinking 5k rotations would avoid this. I'm going to start.
 
I wouldn't bother doing anything other than a rotation if most of those tires' usage was prior to the alignment. Maybe that edge was already worn down a bit extra before that point.

I like to keep the two best tires on the front as much as possible to maintain a consistent tread depth between the four tires. Once the front tires are noticeably more worn than the rears, it's time for a rotation. Just don't use tires that are at the wear bars on the back, and keep the set closely matched in terms of tread wear for balanced handling and traction.
 
After so many thousands of miles on that alignment, who knows if it is still OK?
Alignment can go out after a hit/bump 10 seconds after a good alignment.
FWD cars need rotation more than RWD. I also suspect a bit of toe out on that side.
Keep your cold tire pressure 2-3 lbs over the door sticker, too.
 
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