Abstract: An efficient finite element analysis (FEA) method is presented for multi-body contact problems of a road wheel. This approach combines the Lagrangian multiplier method with the symmetric penalty function. Based on the combined method, the multi-body contact FEA model of road wheel is set up and analyzed. The contact-stress field and extrusion conditions are then obtained. The FEA results show that initial crack comes into being as the maximal Von-Mise stress exceeds the compressive strength limit of rubber. The results also provide a theoretical foundation for calculating crack extension and predicting the road wheel fatigue life.