When using Physics Wheels (not Raycast Wheels), it’s strongly recommended to lower the engine’s Physics Contact Offset values to the minimum values Unreal allows.

By default, Unreal applies a small invisible gap between physics bodies during collision to improve stability. However, for rolling wheels, this can cause an unwanted side effect: wheels will bounce when crossing between separate surfaces, even if the surfaces are perfectly level and aligned. The faster the vehicle moves, the more noticeable and disruptive this bounce becomes.

Reducing both the Min Contact Offset and Max Contact Offset values in the Physics settings (under Project Settings → Physics) significantly reduces or eliminates this behavior.

Note: This issue only applies to Physics Wheel mode. Raycast Wheels are unaffected by contact offset settings.

Also, while this fix was confirmed for UE4, the behavior in UE5 may differ and hasn’t been extensively tested yet. If you're using UE5, test accordingly and adjust as needed.

Unreal Engine applies limits to how fast physics objects can move and spin. These defaults are too low for realistic vehicles, and may prevent wheels from reaching the speeds they’re physically capable of.

Update these settings in Project Settings → Physics:

•     Default Terminal Velocity → 7600 cm/s (≈ 170 MPH)

•     Max Angular Velocity → 10000 deg/s

    For reference:

    A wheel with a 35 cm radius spinning at 10000 degrees per second reaches a linear surface speed of about 6105 cm/s (≈ 136 MPH).

    This means if your wheels need to push past that speed, you'll need to increase this value further.

To calculate:

Linear Speed (cm/s) = (Angular Velocity in deg/s × (π / 180)) × Radius in cm

Set your value high enough that wheels never hit the ceiling under normal operation.