IllustrationWHILE DRIVING ALONG AT 55 MPH ENGINE SHUT DOWN. NO POWER BRAKES, STEERING, ETC. INDICATOR MESSAGE ON DASHBOARD SAID "CHECK ELECTRONIC IGNITION". REPAIR COST $ 724.19. *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
Electrical System complaints
76 reportsFOR THE 3RD TIME IN THE PAST YEAR I AM DRIVING DOWN THE ROAD AT ABOUT 40 MPH - ENGINE LIGHTS COMES ON, MESSAGE "CHECK ELECTRONIC THROTTLE CONTROL" COMES ON - I HAVE NO POWER, I COAST TO THE SIDE LANE TURN ON HAZARD LIGHTS, TURN KEY TO OFF POSITION. RESTART THE CAR (TAKES A COUPLE OF TRIES) AND CONTINUE - THIS IS EXTREMELY DANGE…
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FOR THE 3RD TIME IN THE PAST YEAR I AM DRIVING DOWN THE ROAD AT ABOUT 40 MPH - ENGINE LIGHTS COMES ON, MESSAGE "CHECK ELECTRONIC THROTTLE CONTROL" COMES ON - I HAVE NO POWER, I COAST TO THE SIDE LANE TURN ON HAZARD LIGHTS, TURN KEY TO OFF POSITION. RESTART THE CAR (TAKES A COUPLE OF TRIES) AND CONTINUE - THIS IS EXTREMELY DANGEROUS AND SHOULD BE ADDRESSED BY FORD ( I HAVE REPORTED THIS ISSUE) LOOKING ON LINE AND ON ONE SITE HTTP://WWW.CARCOMPLAINTS.COM/FORD/EXPEDITION/2005/ENGINE/VEHICLE_SPEED_CONTROL.SHTML THERE ARE 52 COMPLAINTS WITH THE SAME ISSUE. THERE ARE MANY OTHER SITES REPORTING THE SAME EXACT PROBLEM. I AM TAKING MY VEHICLE TO THE DEALER TOMORROW - WHAT ELSE SHOULD I BE DOING TO RESOLVE THIS ISSUE. - IT'S APPARENT THAT MANY OTHER PEOPLE ARE HAVING THIS SAME EXACT ISSUE- DOES IT TAKE SOMEONE DYING TO GET THE CAR MANUFACTURERS TO LISTEN TO THEIR CUSTOMERS? *TR
WHILE MOVING IN TRAFFIC THE VEHICLE ENGINE CUT-OFF ON ITS OWN. MESSAGE CAME UP ON DASH DISPLAY, SOMETHING ABOUT "ELECT THROTTLE CONTROL". WAS MOVING VERY SLOWLY ON AN INTERSTATE HIGHWAY BAD TRAFFIC, WITH HEATERS (FRONT AND BACK) AND THE RADIO ON. I WAS ABLE TO COAST OFF TO THE SIDE OF THE HIGHWAY. TURNED OFF RADIO, HEATERS, THEN…
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WHILE MOVING IN TRAFFIC THE VEHICLE ENGINE CUT-OFF ON ITS OWN. MESSAGE CAME UP ON DASH DISPLAY, SOMETHING ABOUT "ELECT THROTTLE CONTROL". WAS MOVING VERY SLOWLY ON AN INTERSTATE HIGHWAY BAD TRAFFIC, WITH HEATERS (FRONT AND BACK) AND THE RADIO ON. I WAS ABLE TO COAST OFF TO THE SIDE OF THE HIGHWAY. TURNED OFF RADIO, HEATERS, THEN WAS ABLE TO RESTART THE VEHICLE. BATTERY CONDITION WAS FINE (REPLACED 2 YEARS AGO), NO OTHER WARNING. VEHICLE IS WELL-MAINTAINED, NEVER DRIVEN HARD OR USED FOR TOWING. TODAY I AM TAKING IT TO A FORD DEALER FOR EVALUATION. *TR
I WAS DRIVING MY 2005 FORD EXPEDITION AT 25MPH AND CAME TO A STOP LIGHT. I STOPPED. I TRIED TO ACCELERATE BUT I COULDN'T. MY RPM WHERE MOVING BUT CAR WOULD NOT. THEN THE CHECK ELECTRIC THROTTLE CONTROL MESSAGE POPPED ON. CAR FINALLY STARTED TO ACCELERATE BUT DIED OUT. IT THEN RESTARTED AND DROVE NORMALLY FOR 4 BLOCKS, BEFORE NOT…
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I WAS DRIVING MY 2005 FORD EXPEDITION AT 25MPH AND CAME TO A STOP LIGHT. I STOPPED. I TRIED TO ACCELERATE BUT I COULDN'T. MY RPM WHERE MOVING BUT CAR WOULD NOT. THEN THE CHECK ELECTRIC THROTTLE CONTROL MESSAGE POPPED ON. CAR FINALLY STARTED TO ACCELERATE BUT DIED OUT. IT THEN RESTARTED AND DROVE NORMALLY FOR 4 BLOCKS, BEFORE NOT ACCELERATING AT ALL. HAD TO BE TOWED TO FORD DEALER. THIS NEEDS TO BE RECALLED. *TR
VEHICLE DIED UNEXPECTEDLY WHILE TRAVELING DOWN HIGHWAY AT A HIGH RATE OF SPEED. THERE ARE HUNDREDS OF COMPLAINTS JUST LIKE THIS ON HERE. IF A RECALL ISN'T IN ORDER PEOPLE WILL DIE AND THE LAWSUITS WILL BEGIN. IT'S OBVIOUSLY A MAJOR MECHANICAL PROBLEM. FORD AND THE NHTSA SHOULD BE LIABLE. THIS IS SERIOUS AND READING THROUGH A…
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VEHICLE DIED UNEXPECTEDLY WHILE TRAVELING DOWN HIGHWAY AT A HIGH RATE OF SPEED. THERE ARE HUNDREDS OF COMPLAINTS JUST LIKE THIS ON HERE. IF A RECALL ISN'T IN ORDER PEOPLE WILL DIE AND THE LAWSUITS WILL BEGIN. IT'S OBVIOUSLY A MAJOR MECHANICAL PROBLEM. FORD AND THE NHTSA SHOULD BE LIABLE. THIS IS SERIOUS AND READING THROUGH ALL OF THESE COMPLAINTS IT DOESN'T SEEM LIKE THE NHTSA IS DOING THEIR JOB. *TR
WHILE DRIVING HOME DOWN A SLIGHT DECLINE, I HEARD A BEEP AND THE MESSAGE ON THE DASH READ (CHECK ELECTRONIC THROTTLE CONTROL) WHICH I THEN MENTALLY ADDED TO MY LIST OF THINGS TO DO. NOT UNTIL A NEEDED TO START ACCELERATING AGAIN DID I REALIZE THAT MY THROTTLE WAS COMPLETELY INOPERABLE. LUCKILY, A WORD USED FREQUENTLY BY OTHER …
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WHILE DRIVING HOME DOWN A SLIGHT DECLINE, I HEARD A BEEP AND THE MESSAGE ON THE DASH READ (CHECK ELECTRONIC THROTTLE CONTROL) WHICH I THEN MENTALLY ADDED TO MY LIST OF THINGS TO DO. NOT UNTIL A NEEDED TO START ACCELERATING AGAIN DID I REALIZE THAT MY THROTTLE WAS COMPLETELY INOPERABLE. LUCKILY, A WORD USED FREQUENTLY BY OTHER OWNERS TO DESCRIBE THIS SAME ISSUE, I WAS ABLE TO COAST TO A STOP WHILE OTHER VEHICLES WENT AROUND ME. TURNING OFF THE VEHICLE AND RESTARTING IT SEEMED TO "RESET" THE THROTTLE CONTROL. I DO NOT TRUST THAT IT WILL BE SAFE TO USE, PARTICULARLY WITH THE WINTER DRIVING CONDITIONS THAT I ENCOUNTER. I HAVE AN APPOINTMENT SCHEDULED FOR MONDAY. WITH ALL THE COMPLAINTS I HAVE SEEN REGARDING THIS SAME ISSUE, I AM SHOCKED THAT MORE ACTION (RECALL) HAS NOT BEEN TAKEN. DOES A CRASH, FIRE, INJURY, OR FATALITY NEED TO OCCUR BEFORE THIS CAN BE TAKEN SERIOUSLY? I AM BAFFLED THAT A WARNING MESSAGE CANNOT BE DISPLAYED IN ADVANCE OF COMPLETE THROTTLE FAILURE CONSIDERING THE POTENTIAL CATASTROPHIC OUTCOMES. THIS VEHICLE WAS INSPECTED/SERVICED NOVEMBER 2013. *TR
WHILE DRIVING 55MPH ON INTERSTATE 95 IN PHILADELPHIA, PA WITH MY WIFE AND 2 CHILDREN THE VEHICLE STOPPED RUNNING AND I WAS DANGEROUSLY STALLED IN THE MIDDLE OF INTERSTATE 95. THE CHECK ENGINE LIGHT CAME ON AND CHECK ELECTRONIC THROTTLE MESSAGE CAME ON. THIS IS A FAMILY VEHICLE AND MY WIFE AND I REFUSE TO DRIVE IT NOW IN FEAR O…
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WHILE DRIVING 55MPH ON INTERSTATE 95 IN PHILADELPHIA, PA WITH MY WIFE AND 2 CHILDREN THE VEHICLE STOPPED RUNNING AND I WAS DANGEROUSLY STALLED IN THE MIDDLE OF INTERSTATE 95. THE CHECK ENGINE LIGHT CAME ON AND CHECK ELECTRONIC THROTTLE MESSAGE CAME ON. THIS IS A FAMILY VEHICLE AND MY WIFE AND I REFUSE TO DRIVE IT NOW IN FEAR OF THIS INCIDENT OCCURRING AGAIN RESULTING IN DEATH OR SERIOUS INJURY. BASED UPON MY RESEARCH, IT APPEARS TO BE A WELL KNOWN PROBLEM THAT OCCURRED TO THOUSANDS OF FORD EXPEDITION OWNERS. I WOULD APPRECIATE THE PROBLEM BEING ADDRESSED EXPEDITIOUSLY BEFORE PEOPLE ARE KILLED AND/OR INJURED. *TR
DRIVING ON HIGHWAY AT ABOUT 60 MPH CHANGING LANES AND A ODB MESSAGE APPEARS "CHECK ELECTRONIC THROTTLE CONTROL" AND THE CAR JUST SHUTS DOWN. IT WAS A LIFE THREATENING MOMENT FOR MY FAMILY AND I AS A TRUCK THAT WAS ON COMING FROM BEHIND WITH SPEED HAD TO SLAM ON THE BRAKES IN ORDER NOT TO COLLIDE WITH ME SINCE I HAD NO POWER TO A…
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DRIVING ON HIGHWAY AT ABOUT 60 MPH CHANGING LANES AND A ODB MESSAGE APPEARS "CHECK ELECTRONIC THROTTLE CONTROL" AND THE CAR JUST SHUTS DOWN. IT WAS A LIFE THREATENING MOMENT FOR MY FAMILY AND I AS A TRUCK THAT WAS ON COMING FROM BEHIND WITH SPEED HAD TO SLAM ON THE BRAKES IN ORDER NOT TO COLLIDE WITH ME SINCE I HAD NO POWER TO ACCELERATE. I WAS ONLY FORTUNATE THAT THE TRUCK HAD A CLEAR LANE TO CHANGE INTO ABRUPTLY. THE ELECTRONIC THROTTLE MESSAGE AFTER FURTHER RESEARCH IS A WIDE SPREAD KNOW ISSUE AMONG FORD CARS AND I AM LIVID AND VERY ANGRY THAT THE NHTSA HAS NOT ISSUED A RECALL ON THIS KNOW ISSUE AS IT IS PUBLIC KNOWLEDGE ONLINE. THIS NEEDS TO BE ADDRESSED IMMEDIATELY TO AVOID ANY POTENTIAL FUTURE TRAGEDIES. I HOPE FORD DOES NOT WANT BLOOD ON THERE HANDS! *TR
I WAS DRIVING WITH 4 KIDS IN THE CAR, WHEN ALL THE SUDDEN MY CAR TURNED OFF, ALL THE LIGHTS CAME ON THE DASH. LUCKILY I WAS ABLE TO MOVE OVER TO A PARKING LOT. I TURNED THE CAR OFF, TURNED BACK ON, NOTHING. TRIED AGAIN AND IT WORKED. I WAS ABLE TO DRIVE 50 MILES HOME AND AS I WAS TURNING IN MY DRIVEWAY IT HAPPENED AGAIN. *TR
REAR DRIVER SIDE PASSENGER WINDOW WENT DOWN BY ITSELF AND THERE IS NO WAY TO SEND IT UP. IS STUCK OPEN. I AM REPORTING BECAUSE I FOUND MORE THAN 20 FORUMS ONLINE WITH HUNDREDS OF REPORTED COMPLAINTS ON THE SAME ISSUE AND I DON'T SEE THE NECESSARY RECALL ON THIS ITEM. *TR
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