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I have 235/60 16 on the actual car and the spare is 215/70 16

If I need to use the spare I would only use it for a maximum of 50 miles to get me home or to a garage

- What are going to be my problems using a different diameter spare - will I break anything?
 

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I'm kinda in the same situation. On my 96 RAV the stock tyre size is 215/70/16. I recently replaced the 4 road tyres with 235/50/18 sized tyres leaving the spare still as 215/70/16. The OD (overall diameter) of the 235/50/18 tyre is about 15mm smaller than the OD of the 215/70/16 tyre. When looking at 235/60/16 compared to 215/70/16 the OD of the former is 19mm smaller than the OD of the latter. On a full time 4WD system you'd want all 4 tyres to have pretty much the same OD. 15 or 19mm difference in OD is a bit too much for my liking.

In my case, i'm going to go with a 235/60/16 tyre for the spare instead of a 215/70/16. Reason being that the OD of this size is only 3.81mm smaller than the OD of my road tyre. That less a difference in OD shouldnt make too much of a difference for a short distance. But a difference of 15 or 19mm would make a difference i'd think.

I'm not even going to run a brand new 235/60/16 tyre as my spare. You can pick up a good used tyre with around 80% tread left for very cheap. I'd suggest that you guys try and do the same thing as its going to save you money and ensure that your OD is not affected.

Here is a pic comparing the 215/70/16 tyre (on the left) with the 235/50/18 tyre mounted on the car (on the right). The difference there is 15mm. If that was a 235/60/16 on the right then add about 4mm more to the difference.

 

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If you are not going far and all you have is a tire that is a little too big, you can just let enough air out of it so that it is the same highet off the ground measured from the top as the other three. Although I have a spare I have a can of foam I would probably use before bothering to change tires, then again I have access to a tire machine to clean it out later :)
 
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