Originally Posted By: Stu_Rock
http://www.tirerack.com/tires/tiretech/techpage.jsp?techid=18
There's quite a bit of misinformation, or more accurately error by omission in that article.
Differentials in all cars have to be able to cope with a difference of a couple centimeters at an absolute minimum. Otherwise, you'd have to adjust your air pressure every time you load the car with cargo or have passengers in the back. Rollout can very significantly within the cargo and passenger limits of the vehicle, 10mm or more (generally, sidewall stiffness is in the order of 230N/mm or so, depending on the tire).
If a car were sensitive to 1/4" tire differences (as Subaru claims) you'd literally seem them strewn by the roadside in droves. It's part CYA on the part of the auto manufacturers (something to blame in case of failure), and part urban legend: "my Volvo bevel gear blew up because I had the wrong size tires!". No, it blew up because you were either driving like an idiot or the bevel gear is under-designed...or both.
Secondly, the article doesn't differentiate between completely manual and electronically-controlled AWD systems. On Haldex units (where wheel speed is measured and sent to the system's computer) and other electronically controlled AWD systems, the difference is even less important. The manufacturer of Haldex states the system will tolerate a difference of up to 8% of rollout diameter. In an 18" wheel w/normal sized tires, that a difference of a couple inches, not mm's.
I certainly agree that putting on a completely different size tire (or donut spare) can damage some (though not all) systems. Claiming that a 3mm difference in tire is going to cause problems though is completely ridiculous.