IllustrationWE WERE SITTING IN TRAFFIC AND WERE REAR-ENDED AT MILEAGE SPEED AND CRASHED INTO THE VEHICLE IN FRONT OF US. THE AIR BAGS DID NOT OPEN. *TR
2005 Ford Expedition
Owner reports · Recalls · Investigations
More warning signs than most Expedition years
Owner complaints for the 2005 Ford Expedition are substantially higher than the model-year median of 155.
About this comparison →How this year compares
Owner complaints by model year
Compare all Expedition years →Counts vary with age, sales and reporting. They are not failure rates.
What owners reported most
All reported categories
Tap a category to read its complaints. One report may name several components.
When problems were reported
Mileage at the reported incident
250–25K
4025–50K
7950–75K
6275–100K
60100–150K
23150K+
289 reports with mileage · 26 unknown
NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.
What to inspect
Issues worth paying extra attention to based on owner reports.
- Electrical System. Review the 76 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Vehicle Speed Control. Review the 66 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Engine. Review the 57 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
NHTSA owner reports · September 18, 2026 snapshot.
20 crash reports6 fire reports10 injury reports
Air Bags complaints
9 reportsI WAS DRIVING MY 2005 FORD EXPEDITION WEST ON EISENHOWER BLVD AT ABOUT 25 MPH. I PROCEEDED THROUGH THE INTERSECTION OF EISENHOWER AND CLEVELAND AVE WHEN A PICK-UP TRUCK RAN A RED LIGHT AND COLLIDED WITH THE RIGHT FRONT OF MY VEHICLE. MY VEHICLE SUSTAINED EXTENSIVE DAMAGE TO THE FRONT BUMPER, RIGHT FRONT FENDER AND FRONT PASSEN…
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I WAS DRIVING MY 2005 FORD EXPEDITION WEST ON EISENHOWER BLVD AT ABOUT 25 MPH. I PROCEEDED THROUGH THE INTERSECTION OF EISENHOWER AND CLEVELAND AVE WHEN A PICK-UP TRUCK RAN A RED LIGHT AND COLLIDED WITH THE RIGHT FRONT OF MY VEHICLE. MY VEHICLE SUSTAINED EXTENSIVE DAMAGE TO THE FRONT BUMPER, RIGHT FRONT FENDER AND FRONT PASSENGER DOOR, COMPLETELY DISLODGING THE RIGHT FRONT WHEEL AND BUCKLING THE FRAME OF THE VEHICLE. I SUSTAINED INJURIES, INCLUDING A BRUISED STERNUM AND BRUISED LUNGS. NEITHER FRONT AIRBAG DEPLOYED, WHICH WOULD HAVE MITIGATED MY INJURIES!
IN TRYING TO AVOID DEBRIS THE SUV FLIP AND SLIDING DOWN THE HWY I HIT A TRACTOR TRAILER REAR TIRE,THE AIR BAGS DID NOT DEPLOY. *TT
MY WIFE AND 3 CHILDREN WERE DRIVING MY 2005 FORD EXPEDITION DOWN HWY 29 IN LAKE COUNTY, CA. WHEN THE 2 FRONT AIRBAGS SUDDENLY DEPLOYED. THERE WAS NO ACCIDENT OR IMPACT. LUCKILY MY WIFE WAS ABLE TO RETAIN CONTROL OF THE VEHICLE BUT HAS INJURIES HER CHEST AND NECK. THE CODES FROM THE VEHICLE DO NOT INDICATE ANY ERROR OR MALFUNCTI…
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MY WIFE AND 3 CHILDREN WERE DRIVING MY 2005 FORD EXPEDITION DOWN HWY 29 IN LAKE COUNTY, CA. WHEN THE 2 FRONT AIRBAGS SUDDENLY DEPLOYED. THERE WAS NO ACCIDENT OR IMPACT. LUCKILY MY WIFE WAS ABLE TO RETAIN CONTROL OF THE VEHICLE BUT HAS INJURIES HER CHEST AND NECK. THE CODES FROM THE VEHICLE DO NOT INDICATE ANY ERROR OR MALFUNCTION. IT WOULD MAKE SENSE THAT THIS INCIDENT IS RELATED TO THE F-150 RECALL ISSUE. *TR
TL*THE CONTACT OWNS A 2005 FORD EXPEDITION. WHILE DRIVING BETWEEN 55-60 MPH, A TRACTOR TRAILER MERGED OVER AND CAUSED THE CONTACT TO CRASH INTO A TREE. NONE OF THE AIR BAGS DEPLOYED IN THE VEHICLE. THE CONTACT SUSTAINED FACIAL INJURIES AND THREE OTHER PASSENGERS SUSTAINED MINOR INJURIES. ONE OCCUPANT SUFFERED MAJOR INJURIES.…
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TL*THE CONTACT OWNS A 2005 FORD EXPEDITION. WHILE DRIVING BETWEEN 55-60 MPH, A TRACTOR TRAILER MERGED OVER AND CAUSED THE CONTACT TO CRASH INTO A TREE. NONE OF THE AIR BAGS DEPLOYED IN THE VEHICLE. THE CONTACT SUSTAINED FACIAL INJURIES AND THREE OTHER PASSENGERS SUSTAINED MINOR INJURIES. ONE OCCUPANT SUFFERED MAJOR INJURIES. THE VEHICLE WAS DESTROYED. THERE WAS ADDITIONAL PROPERTY DAMAGE TO THE HIGHWAY MEDIAN. A POLICE REPORT WAS FILED. ALL OF THE PASSENGERS WERE WEARING SEAT BELTS AT THE TIME OF THE CRASH. THERE WERE NO REPAIRS MADE TO THE AIR BAGS PRIOR TO THE CRASH. THE VEHICLE HAS NOT BEEN INSPECTED BY A DEALER. THE CONTACT'S INSURANCE COMPANY IS REVIEWING THE DAMAGE AND SENDING A RECONSTRUCTIONIST TO INVESTIGATE. THE CURRENT AND FAILURE MILEAGES WERE 85,000.
TL*THE CONTACT OWNS A 2005 FORD EXPEDITION. WHILE DRIVING ON A WET ROAD AT 45 MPH, THE BACK OF THE VEHICLE BEGAN TO SLIDE. THE CONTACT WAS HIT BY ANOTHER VEHICLE AND SPUN OUT OF CONTROL ACROSS FOUR LANES OF TRAFFIC. THE BACK END OF THE VEHICLE CRASHED INTO A CEMENT BARRACADE. A VEHICLE THAT WAS ENTERING THE HIGHWAY CRASHED INTO…
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TL*THE CONTACT OWNS A 2005 FORD EXPEDITION. WHILE DRIVING ON A WET ROAD AT 45 MPH, THE BACK OF THE VEHICLE BEGAN TO SLIDE. THE CONTACT WAS HIT BY ANOTHER VEHICLE AND SPUN OUT OF CONTROL ACROSS FOUR LANES OF TRAFFIC. THE BACK END OF THE VEHICLE CRASHED INTO A CEMENT BARRACADE. A VEHICLE THAT WAS ENTERING THE HIGHWAY CRASHED INTO THE DRIVERS SIDE. THE AIR BAGS NEVER DEPLOYED. THE AMBULANCE AND POLICE ARRIVED AND TRANSPORTED THE CONTACT TO THE HOSPITAL. THE VEHICLE WAS DESTROYED. THE MANUFACTURER WAS NOTIFIED, THE CONTACT HAS BEEN UNSUCCESSFUL AT SPEAKING WITH THEM. THE CURRENT AND FAILURE MILEAGE WAS 75,000.
DT*: THE CONTACT STATED WHILE DRIVING 30 MPH ON A WET HIGHWAY, THE CONTACT'S SPOUSE BROADSIDED ANOTHER VEHICLE AND THE AIR BAGS DID NOT DEPLOY. THE SEAT BELT WAS IN USE AND WORKED PROPERLY. A POLICE REPORT WAS TAKEN. THERE WAS FRONT END DAMAGE DONE TO THE VEHICLE. THE ONLY LIGHT ILLUMINATED IN THE VEHICLE WAS A LIGHT INDICAT…
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DT*: THE CONTACT STATED WHILE DRIVING 30 MPH ON A WET HIGHWAY, THE CONTACT'S SPOUSE BROADSIDED ANOTHER VEHICLE AND THE AIR BAGS DID NOT DEPLOY. THE SEAT BELT WAS IN USE AND WORKED PROPERLY. A POLICE REPORT WAS TAKEN. THERE WAS FRONT END DAMAGE DONE TO THE VEHICLE. THE ONLY LIGHT ILLUMINATED IN THE VEHICLE WAS A LIGHT INDICATING THE GAS CAP WAS LOOSE. THE DEALERSHIP WAS NOT ALERTED. THE DRIVER SUSTAINED SOFT TISSUE DAMAGE. UPDATED 10/25/06. *JB
DT: THE CONTACT'S HUSBAND RENTED A 2005 FORD EXPEDITION. THE CONTACT STATED WHILE HER HUSBAND WAS DRIVING THE VEHICLE BEGAN TO HYDROPLANE , CAUSING IT TO HIT A TREE. AS THE VEHICLE HYDROPLANED IT TURNED SIDEWAYS AWAY FROM THE SHOULDER AND HIT A TREE FROM THE SIDE. UPON IMPACT, THE AIR BAGS DID NOT DEPLOY. THE VEHICLE I…
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DT: THE CONTACT'S HUSBAND RENTED A 2005 FORD EXPEDITION. THE CONTACT STATED WHILE HER HUSBAND WAS DRIVING THE VEHICLE BEGAN TO HYDROPLANE , CAUSING IT TO HIT A TREE. AS THE VEHICLE HYDROPLANED IT TURNED SIDEWAYS AWAY FROM THE SHOULDER AND HIT A TREE FROM THE SIDE. UPON IMPACT, THE AIR BAGS DID NOT DEPLOY. THE VEHICLE IS EQUIPPED WITH THE FRONT AND THE SIDE AIR BAGS. THE CONTACT DID NOT KNOW WHAT TYPES OF AIR BAGS ARE IN THIS VEHICLE. THE CONSUMER HAS CONTACTED THE RENTAL CAR AGENCY, BUT HAS NOT INFORMED THEM THAT THE AIR BAGS DID NOT DEPLOY IN THE VEHICLE. THE CONSUMER HAS NOT CONTACTED THE MANUFACTURER.*AK
I WAS TRAVELING AT 50MPH IN MY 2005 FORD EXPEDITION (3,700 MILES) WHEN A CHEVY CAVALIER RAN A STOP SIGN. I IMPACTED THE VEHICLE WITHOUT HAVING AN OPPORTUNITY TO HIT MY BRAKES. I WAS THE SOLE PERSON IN THE VEHICLE. IMPACT DESTROYED THE FRONT END OF MY VEHIVLE, AND PUSHED THE PASSENGER SIDE OF THE CAVALIER TO THE DRIVERS SEAT. MY …
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I WAS TRAVELING AT 50MPH IN MY 2005 FORD EXPEDITION (3,700 MILES) WHEN A CHEVY CAVALIER RAN A STOP SIGN. I IMPACTED THE VEHICLE WITHOUT HAVING AN OPPORTUNITY TO HIT MY BRAKES. I WAS THE SOLE PERSON IN THE VEHICLE. IMPACT DESTROYED THE FRONT END OF MY VEHIVLE, AND PUSHED THE PASSENGER SIDE OF THE CAVALIER TO THE DRIVERS SEAT. MY VEHICLE THEN EXITED THE ROAD THROUGH A STAND OF TREES, DOWN AN EMBANKMENT AND CAME TO REST ON THE FAR SIDE OF THE EMBANKMENT. FAILURE: PASSNGER AIRBAG DEPLOYED, BUT DRIVER'S AIRBAG DID NOT, RESULTING IN NECK INJURIES. MAJORITY OF DAMAGE WAS TO DRIVER'S SIDE OF FRONT END. FORD HAS EXPRESSED NO INTEREST AS TO THE CAUSE OF THE AIRBAG FAILURE.
Official recalls
0No recalls in this snapshot.
Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗
NHTSA investigations
1PE08070 · Steel Wheel Fracture
Opened Dec 9, 2008 · Closed Apr 15, 2009
Status: closed (inferred from source dates) · Wheels; Wheels:rim
FORD SPECIAL SERVICE VEHICLE (SSV) EXPEDITIONS USE A STEEL FULL FACE WHEEL DESIGN SIMILAR TO THAT INVESTIGATED IN PE03009, RQ04007, EA04034 (CROWN VICTORIA POLICE INTERCEPTOR) AND PE03026 (GM PICKUPS AND SUVS).A TOTAL OF 8,251 SSVS (2.2% OF TOTAL PRODUCTION) WERE PRODUCED WITHIN MODEL YEARS 2004-2006 AND SOLD PRIMARILY FOR USE BY STATE, FEDERAL, AND MUNICIPAL LAW ENFORCEMENT (LE) AGENCIES.FORD STIPULATES THAT THE SUBJECT VEHICLES ARE NOT SUITABLE FOR HIGH SPEED OR PURSUIT OPERATIONS AND ALSO IDENTIFIED A 2004 NATIONAL INSTITUTE FOR JUSTICE VEHICLE EVALUATION REPORT WHICH ALSO ACKNOWLEDGES THIS LIMITATION. THE FULL FACE WHEEL IS FABRICATED FROM TWO PIECES: A STAMPED OUTER WHEEL DISC AND A FORMED RIM.THE TWO PIECES, WHICH TOGETHER COMPRISE THE OUTER BEAD SEAT, ARE JOINED TOGETHER WITH A CIRCUMFERENTIAL WELD.A CYCLIC BENDING MOMENT OCCURS IN THE OUTER BEAD SEAT AREA AS THE WHEEL ROTATES, RESULTING IN FATIGUE STRESSES IN THE WELD'S HEAT AFFECTED ZONE THAT CAN LEAD TO FRACTURING (CRACKING) OF THE RIM MATERIAL.BECAUSE THE FAILURE OCCURS UNDER THE OUTBOARD TIRE BEAD, AIR LEAKAGE MAY NOT READILY OCCUR WHEN THE RIM CRACKS, DEPENDENT ON HOW WELL THE BEAD SEALS ON THE RIM.IF MULTIPLE CRACKS GROW UNDETECTED AND SUDDENLY JOIN INTO A SINGLE LARGE CRACK, THE WHEEL'S STRUCTURE CAN BECOME COMPROMISED LEADING TO RAPID AIR LOSS.A RAPID AIR LOSS, ESPECIALLY AT HIGHER SPEED, MAY LEAD TO A CRASH. FORD RESPONDED TO ODI'S JANUARY 5, 2009 INFORMATION REQUEST (IR) ON FEBRUARY 24.FORD'S RESPONSE ACKNOWLEDGES A NUMBER OF WHEEL FRACTURES ON THE SSVS.HOWEVER, BASED ON ITS ASSESSMENT OF THE PERTINENT FACTORS, IT CONCLUDES THAT THE CONDITION DOES NOT REPRESENT AN UNREASONABLE RISK TO SAFETY.THE LACK OF REPORTS OF RAPID AIR LOSS, NO ALLEGED CRASHES, AND THEIR ASSESSMENT THAT A CRACKED WHEEL CAN BE DETECTED THROUGH SLOW, REPEATED AIR LOSS OR VIBRATION, WERE THE BASES FOR FORD'S CONCLUSION.FORD DISCUSSES THE RESULTS OF A STUDY IT PERFORMED ON WHEELS RETURNED FROM LE FIELD USE, DESIGN REVISIONS IT MADE TO THE SUBJECT WHEEL, AND THE OUTCOME OF DURABILITY TESTING IT CONDUCTED ON THE OLD AND NEW WHEEL DESIGNS. THE COUNTS SHOWN ABOVE INCLUDE A DUPLICATE ODI AND FORD REPORT; THE FORD COUNTS ARE UNIQUE VEHICLES ALLEGING WHEEL FRACTURE(S).SOME WARRANTY CLAIMS INVOLVED MORE THAN ONE WHEEL REPLACEMENT.ALTHOUGH THE SUBJECT VEHICLES HAVE BEEN IN SERVICE FOR A LONGER PERIOD OF TIME THAN VEHICLES INVESTIGATED IN THE PREVIOUS INVESTIGATIONS OF TWO-PIECE WHEEL FRACTURE, ODI DID NOT IDENTIFY ANY ALLEGATIONS OF CRASHES, RAPID AIR LOSS EVENTS DUE TO WHEEL FRACTURES OR ALLEGATIONS OF EFFECTS ON VEHICLE CONTROL OR STABILITY, AS WERE THE CASES IN PAST INVESTIGATIONS WHERE SAFETY RECALLS WERE CONDUCTED TO REPLACE AFFECTED WHEELS.THE AGENCY AGREES THAT THE SSV IS NOT SUITABLE FOR PURSUIT OR HIGH SPEED USAGE, REDUCING THE POTENTIAL FOR CRASHES OR LOSS OF CONTROL INCIDENTS TO BE CAUSED BY THE ALLEGED DEFECT. FORD IMPLEMENTED A 'SHOT PEENING' PROCESS IN JUNE 2006 WHICH REDUCED THE WHEEL'S SURFACE STRESS AND SIGNIFICANTLY IMPROVED ITS DURABILITY, AND ODI IS UNAWARE OF ANY FAILURES OF SHOT PEENED WHEELS (SERVICE PART NUMBER 7L1Z-1015-B).FORD'S TESTING SHOWED A SLIGHTLY REDUCED DURABILITY FOR THE NON-SHOT PEENED WHEELS WHEN 'LT' INSTEAD OF FORD APPROVED 'P' METRIC TYPE TIRES ARE USED. A SAFETY-RELATED DEFECT HAS NOT BEEN IDENTIFIED AT THIS TIME AND FURTHER USE OF AGENCY RESOURCES DOES NOT APPEAR TO BE WARRANTED.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST.THE AGENCY WILL TAKE FURTHER ACTION IF WARRANTED BY FURTHER C
Additional source detail variants (2)
Wheels
FORD SPECIAL SERVICE VEHICLE (SSV) EXPEDITIONS USE A STEEL FULL FACE WHEEL DESIGN SIMILAR TO THAT INVESTIGATED IN PE03009, RQ04007, EA04034 (CROWN VICTORIA POLICE INTERCEPTOR) AND PE03026 (GM PICKUPS AND SUVS).A TOTAL OF 8,251 SSVS (2.2% OF TOTAL PRODUCTION) WERE PRODUCED WITHIN MODEL YEARS 2004-2006 AND SOLD PRIMARILY FOR USE BY STATE, FEDERAL, AND MUNICIPAL LAW ENFORCEMENT (LE) AGENCIES.FORD STIPULATES THAT THE SUBJECT VEHICLES ARE NOT SUITABLE FOR HIGH SPEED OR PURSUIT OPERATIONS AND ALSO IDENTIFIED A 2004 NATIONAL INSTITUTE FOR JUSTICE VEHICLE EVALUATION REPORT WHICH ALSO ACKNOWLEDGES THIS LIMITATION. THE FULL FACE WHEEL IS FABRICATED FROM TWO PIECES: A STAMPED OUTER WHEEL DISC AND A FORMED RIM.THE TWO PIECES, WHICH TOGETHER COMPRISE THE OUTER BEAD SEAT, ARE JOINED TOGETHER WITH A CIRCUMFERENTIAL WELD.A CYCLIC BENDING MOMENT OCCURS IN THE OUTER BEAD SEAT AREA AS THE WHEEL ROTATES, RESULTING IN FATIGUE STRESSES IN THE WELD'S HEAT AFFECTED ZONE THAT CAN LEAD TO FRACTURING (CRACKING) OF THE RIM MATERIAL.BECAUSE THE FAILURE OCCURS UNDER THE OUTBOARD TIRE BEAD, AIR LEAKAGE MAY NOT READILY OCCUR WHEN THE RIM CRACKS, DEPENDENT ON HOW WELL THE BEAD SEALS ON THE RIM.IF MULTIPLE CRACKS GROW UNDETECTED AND SUDDENLY JOIN INTO A SINGLE LARGE CRACK, THE WHEEL'S STRUCTURE CAN BECOME COMPROMISED LEADING TO RAPID AIR LOSS.A RAPID AIR LOSS, ESPECIALLY AT HIGHER SPEED, MAY LEAD TO A CRASH. FORD RESPONDED TO ODI'S JANUARY 5, 2009 INFORMATION REQUEST (IR) ON FEBRUARY 24.FORD'S RESPONSE ACKNOWLEDGES A NUMBER OF WHEEL FRACTURES ON THE SSVS.HOWEVER, BASED ON ITS ASSESSMENT OF THE PERTINENT FACTORS, IT CONCLUDES THAT THE CONDITION DOES NOT REPRESENT AN UNREASONABLE RISK TO SAFETY.THE LACK OF REPORTS OF RAPID AIR LOSS, NO ALLEGED CRASHES, AND THEIR ASSESSMENT THAT A CRACKED WHEEL CAN BE DETECTED THROUGH SLOW, REPEATED AIR LOSS OR VIBRATION, WERE THE BASES FOR FORD'S CONCLUSION.FORD DISCUSSES THE RESULTS OF A STUDY IT PERFORMED ON WHEELS RETURNED FROM LE FIELD USE, DESIGN REVISIONS IT MADE TO THE SUBJECT WHEEL, AND THE OUTCOME OF DURABILITY TESTING IT CONDUCTED ON THE OLD AND NEW WHEEL DESIGNS. THE COUNTS SHOWN ABOVE INCLUDE A DUPLICATE ODI AND FORD REPORT; THE FORD COUNTS ARE UNIQUE VEHICLES ALLEGING WHEEL FRACTURE(S).SOME WARRANTY CLAIMS INVOLVED MORE THAN ONE WHEEL REPLACEMENT.ALTHOUGH THE SUBJECT VEHICLES HAVE BEEN IN SERVICE FOR A LONGER PERIOD OF TIME THAN VEHICLES INVESTIGATED IN THE PREVIOUS INVESTIGATIONS OF TWO-PIECE WHEEL FRACTURE, ODI DID NOT IDENTIFY ANY ALLEGATIONS OF CRASHES, RAPID AIR LOSS EVENTS DUE TO WHEEL FRACTURES OR ALLEGATIONS OF EFFECTS ON VEHICLE CONTROL OR STABILITY, AS WERE THE CASES IN PAST INVESTIGATIONS WHERE SAFETY RECALLS WERE CONDUCTED TO REPLACE AFFECTED WHEELS.THE AGENCY AGREES THAT THE SSV IS NOT SUITABLE FOR PURSUIT OR HIGH SPEED USAGE, REDUCING THE POTENTIAL FOR CRASHES OR LOSS OF CONTROL INCIDENTS TO BE CAUSED BY THE ALLEGED DEFECT. FORD IMPLEMENTED A 'SHOT PEENING' PROCESS IN JUNE 2006 WHICH REDUCED THE WHEEL'S SURFACE STRESS AND SIGNIFICANTLY IMPROVED ITS DURABILITY, AND ODI IS UNAWARE OF ANY FAILURES OF SHOT PEENED WHEELS (SERVICE PART NUMBER 7L1Z-1015-B).FORD'S TESTING SHOWED A SLIGHTLY REDUCED DURABILITY FOR THE NON-SHOT PEENED WHEELS WHEN 'LT' INSTEAD OF FORD APPROVED 'P' METRIC TYPE TIRES ARE USED. A SAFETY-RELATED DEFECT HAS NOT BEEN IDENTIFIED AT THIS TIME AND FURTHER USE OF AGENCY RESOURCES DOES NOT APPEAR TO BE WARRANTED.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST.THE AGENCY WILL TAKE FURTHER ACTION IF WARRANTED BY FURTHER C
Wheels:rim
FORD SPECIAL SERVICE VEHICLE (SSV) EXPEDITIONS USE A STEEL FULL FACE WHEEL DESIGN SIMILAR TO THAT INVESTIGATED IN PE03009, RQ04007, EA04034 (CROWN VICTORIA POLICE INTERCEPTOR) AND PE03026 (GM PICKUPS AND SUVS).A TOTAL OF 8,251 SSVS (2.2% OF TOTAL PRODUCTION) WERE PRODUCED WITHIN MODEL YEARS 2004-2006 AND SOLD PRIMARILY FOR USE BY STATE, FEDERAL, AND MUNICIPAL LAW ENFORCEMENT (LE) AGENCIES.FORD STIPULATES THAT THE SUBJECT VEHICLES ARE NOT SUITABLE FOR HIGH SPEED OR PURSUIT OPERATIONS AND ALSO IDENTIFIED A 2004 NATIONAL INSTITUTE FOR JUSTICE VEHICLE EVALUATION REPORT WHICH ALSO ACKNOWLEDGES THIS LIMITATION. THE FULL FACE WHEEL IS FABRICATED FROM TWO PIECES: A STAMPED OUTER WHEEL DISC AND A FORMED RIM.THE TWO PIECES, WHICH TOGETHER COMPRISE THE OUTER BEAD SEAT, ARE JOINED TOGETHER WITH A CIRCUMFERENTIAL WELD.A CYCLIC BENDING MOMENT OCCURS IN THE OUTER BEAD SEAT AREA AS THE WHEEL ROTATES, RESULTING IN FATIGUE STRESSES IN THE WELD'S HEAT AFFECTED ZONE THAT CAN LEAD TO FRACTURING (CRACKING) OF THE RIM MATERIAL.BECAUSE THE FAILURE OCCURS UNDER THE OUTBOARD TIRE BEAD, AIR LEAKAGE MAY NOT READILY OCCUR WHEN THE RIM CRACKS, DEPENDENT ON HOW WELL THE BEAD SEALS ON THE RIM.IF MULTIPLE CRACKS GROW UNDETECTED AND SUDDENLY JOIN INTO A SINGLE LARGE CRACK, THE WHEEL'S STRUCTURE CAN BECOME COMPROMISED LEADING TO RAPID AIR LOSS.A RAPID AIR LOSS, ESPECIALLY AT HIGHER SPEED, MAY LEAD TO A CRASH. FORD RESPONDED TO ODI'S JANUARY 5, 2009 INFORMATION REQUEST (IR) ON FEBRUARY 24.FORD'S RESPONSE ACKNOWLEDGES A NUMBER OF WHEEL FRACTURES ON THE SSVS.HOWEVER, BASED ON ITS ASSESSMENT OF THE PERTINENT FACTORS, IT CONCLUDES THAT THE CONDITION DOES NOT REPRESENT AN UNREASONABLE RISK TO SAFETY.THE LACK OF REPORTS OF RAPID AIR LOSS, NO ALLEGED CRASHES, AND THEIR ASSESSMENT THAT A CRACKED WHEEL CAN BE DETECTED THROUGH SLOW, REPEATED AIR LOSS OR VIBRATION, WERE THE BASES FOR FORD'S CONCLUSION.FORD DISCUSSES THE RESULTS OF A STUDY IT PERFORMED ON WHEELS RETURNED FROM LE FIELD USE, DESIGN REVISIONS IT MADE TO THE SUBJECT WHEEL, AND THE OUTCOME OF DURABILITY TESTING IT CONDUCTED ON THE OLD AND NEW WHEEL DESIGNS. THE COUNTS SHOWN ABOVE INCLUDE A DUPLICATE ODI AND FORD REPORT; THE FORD COUNTS ARE UNIQUE VEHICLES ALLEGING WHEEL FRACTURE(S).SOME WARRANTY CLAIMS INVOLVED MORE THAN ONE WHEEL REPLACEMENT.ALTHOUGH THE SUBJECT VEHICLES HAVE BEEN IN SERVICE FOR A LONGER PERIOD OF TIME THAN VEHICLES INVESTIGATED IN THE PREVIOUS INVESTIGATIONS OF TWO-PIECE WHEEL FRACTURE, ODI DID NOT IDENTIFY ANY ALLEGATIONS OF CRASHES, RAPID AIR LOSS EVENTS DUE TO WHEEL FRACTURES OR ALLEGATIONS OF EFFECTS ON VEHICLE CONTROL OR STABILITY, AS WERE THE CASES IN PAST INVESTIGATIONS WHERE SAFETY RECALLS WERE CONDUCTED TO REPLACE AFFECTED WHEELS.THE AGENCY AGREES THAT THE SSV IS NOT SUITABLE FOR PURSUIT OR HIGH SPEED USAGE, REDUCING THE POTENTIAL FOR CRASHES OR LOSS OF CONTROL INCIDENTS TO BE CAUSED BY THE ALLEGED DEFECT. FORD IMPLEMENTED A 'SHOT PEENING' PROCESS IN JUNE 2006 WHICH REDUCED THE WHEEL'S SURFACE STRESS AND SIGNIFICANTLY IMPROVED ITS DURABILITY, AND ODI IS UNAWARE OF ANY FAILURES OF SHOT PEENED WHEELS (SERVICE PART NUMBER 7L1Z-1015-B).FORD'S TESTING SHOWED A SLIGHTLY REDUCED DURABILITY FOR THE NON-SHOT PEENED WHEELS WHEN 'LT' INSTEAD OF FORD APPROVED 'P' METRIC TYPE TIRES ARE USED. A SAFETY-RELATED DEFECT HAS NOT BEEN IDENTIFIED AT THIS TIME AND FURTHER USE OF AGENCY RESOURCES DOES NOT APPEAR TO BE WARRANTED.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST.THE AGENCY WILL TAKE FURTHER ACTION IF WARRANTED BY FURTHER C