Sash wrote:Is this a pure assumption or you have some data (f.e. from debugger ?)
I believe if wheel jumps in "micro" distances it affects contact forces only by a "micro" amounts then.
Sorry no real data, just experience.

I had very exact problem a while a go, with my long lost project. If you look carefully the code for suspension(in Wheel Joint class), you will see that suspension will NEVER REST. That means it will constantly change force applied to the vehicle and most important to wheels. Because wheels are purely rigid in newton in contrast to RL materials(RL tires are constantly contracting and expanding), they will not keep constant connection to the ground(which explains why i had to set friction koef to 16.0 instead of RL 0.7, so if i am correct every 22(=16/0.7) ticks wheel establishes connection and then releases it.)
So to solve this problem, collision check will need error distance checking(in case of small(error) distances from ground will still be counted as collision), Julio correct me if i am wrong!
I will test my theory when i get some free time, which now is very khm none, but i am very sure this is the problem.
Edit:
Sash wrote:p.s. Although I posted my doubts, I'm very interested in getting working vehicle in the end.
p.p.s. Probably it needs to log and compare contacts data for steady and spinning tires.
Even if you make wheels without a suspension you will get the same problem because joints are not rigid and they are acting like "suspension". You can test that with Hinges and very heavy chassy.