Took advantage of Pirelli's warranty at America's tire. My rear passenger tire had an impact bubble from my wife going through another pothole
However, I wasn't as lucky as the OP. My America's Tire store wasn't familiar with Pirelli's road hazard replacement warranty and it required some haggling with the "senior" store manager and having Pirelli call him directly. He then had to call and receive approval from his regional manager. Even after that, the store didn't replace the tire for free like the OP.
I'm still happy though as I only paid ~$100 in total for the replacement. America's Tire still charged me for installation/balancing, state tire fee, and pro-rated cost (based on the % of of original tread remaining and tire msrp). The tire itself ended up costing around ~$80 with their pro-rated amount. This is still a great deal considering the OEM Tesla Pirelli PZERO PZ4 msrp is $294 at America's Tire and $400 at Tesla. It's ~1/5th what we paid when we had to call Tesla's road side service for our last tire sidewall blowout ($490). So if you have the option of taking the time of finding an authorized Pirelli retailer and are able to get your car (or at least tire) to the store, then I highly recommend taking advantage of the warranty.
Like the OP stated, the tire must be within the first 2/32" of tread. We've owned the car for ~4 months and 2500 miles. We were already at the minimum tread cutoff limit for the warranty (7/32" vs 9/32" when new). The store does have to ship the tire back to Pirelli for verification and inspection.
If you really feel like battling with the tire store and want the replacement for completely free, be sure to point out this clause in the Pirelli Road Hazard Warranty to them since our tires are equipped with PNCS & sensors. My local tire store may have confused it with Pirelli's standard pro-rata warranty or they just wanted to make some money out of the process since it is a bit of a hassle for them.
Road Hazard Coverage for Run Flat, Pirelli Noise Cancelling System (PNCS), and sensorized tires
Pirelli provides road hazard coverage on Pirelli Original Equipment Tires and Replacement Tires
that are sensorized or manufactured with Pirelli Run Flat and/or PNCS technology.
If a Pirelli Run Flat, PNCS or sensorized tire becomes unserviceable due to road hazard
damage within the first year from the date of purchase, or within the first 2/32” of the original
usable tread, whichever occurs first, the Pirelli tire will be replaced with an identical or
comparable tire at no charge for the tire to the owner.
Here was the response from Pirelli when I first contacted them about the warranty:
We are sorry to hear that you are experiencing trouble with your tire. America's Tire is an authorized Pirelli dealer and is very familiar with our warranty. You shouldn't need any forms or paperwork prior to arriving at the dealer. As long as the tire measures within the first 2/32" of tread, they should be able to process a warranty claim for you and have a replacement tire installed.
Thank you,
Pirelli Consumer Affairs
[email protected]
1-800-PIRELLI (option 2)
Clearly my America's Tire store wasn't familiar with their warranty. It's located less than 5 miles from the Tesla dealership so I'm assuming not many people are familiar with Pirelli's road hazard warranty to take advantage of it.
We will eventually purchase a set of lighter, smaller diameter rims with PS4S tires for some more sidewall. The 20x9.0" wheels paired with the stretched/skinny 235 width Pirelli tires leads to far too many headaches if you have any potholes in your area. You can understand why by just looking at the sidewall (or lack thereof) at the bottom of the wheel. The rim looks like it's practically sitting on the ground. While the 235/35R20 tire is rated with a sidewall of 3.2" (unloaded), the actual rim is < 2" from the ground once the tire is installed on the car, loaded with the vehicle's weight, and the sidewall angle is accounted for due to stretched nature of the narrower tire on a wider wheel (235mm tire on 9.0" wheel).