NHTSA owner reports · September 18, 2026 snapshot.
Electrical System complaints
76 reportsClear category filter52,000 miles · Apr 6, 2009
Electrical SystemVehicle Speed Control
I WAS DRIVING 55MPH ON HIGHWAY, WHEN ALL OF A SUDDEN THERE WAS NO POWER TO GAS PEDAL. THE CHECK ELECTRONIC THROTTLE CONTROL LIGHT FLASHED, I PULLED OVER THREE LANES TO SIDE OF ROAD. I SAT THERE TRYING TO START VEHICLE CONTINUOUSLY, FINALLY AFTER 10 MINUTES IT STARTED. MY 9 MONTH OLD DAUGHTER AND I WAS ALMOST KILLED ON THE HIGHWA…
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I WAS DRIVING 55MPH ON HIGHWAY, WHEN ALL OF A SUDDEN THERE WAS NO POWER TO GAS PEDAL. THE CHECK ELECTRONIC THROTTLE CONTROL LIGHT FLASHED, I PULLED OVER THREE LANES TO SIDE OF ROAD. I SAT THERE TRYING TO START VEHICLE CONTINUOUSLY, FINALLY AFTER 10 MINUTES IT STARTED. MY 9 MONTH OLD DAUGHTER AND I WAS ALMOST KILLED ON THE HIGHWAY DUE TO THIS PROBLEM. MY VEHICLE IS NOW RUNNING TERRIBLE. I CAME HOME TO SEE IF I COULD FIND ANYTHING ON THE INTERNET AND FOUND THAT THIS IS COMMON IN THE 2005 FORD EXPEDITION AND NOTHING IS BEING DONE. IS IT GOING TO TAKE SOMEONE GETTING KILLED FOR FORD TO RECALL THIS PROBLEM? IT OBVIOUSLY IS A MANUFACTURING PROBLEM AND THEY ARE DOING NOTHING ABOUT IT. I WILL BE CONTACTING FORD TOMORROW TO SEE ABOUT GETTING MY VEHICLE IN AND FIXING THIS. *TR
NHTSA ODI #10264202
40,852 miles · Apr 5, 2009
Electrical System
AS I WAS DRIVING TO MY OFFICE SHORTLY AFTER NOON TODAY, AN ALERT APPEARED "CHECK ELECTRONIC THROTTLE SYSTEM." MY EXPEDITION WOULD NOT ACCELERATE, I COASTED INTO A PARKING LOT AND TRIED TO ACCELERATE, BUT NOTHING HAPPENED. I TURNED OFF THE ENGINE AND RESTARTED MY VEHICLE - I COULD THEN ACCELERATE MY VEHICLE AND CONTINUED TO MY …
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AS I WAS DRIVING TO MY OFFICE SHORTLY AFTER NOON TODAY, AN ALERT APPEARED "CHECK ELECTRONIC THROTTLE SYSTEM." MY EXPEDITION WOULD NOT ACCELERATE, I COASTED INTO A PARKING LOT AND TRIED TO ACCELERATE, BUT NOTHING HAPPENED. I TURNED OFF THE ENGINE AND RESTARTED MY VEHICLE - I COULD THEN ACCELERATE MY VEHICLE AND CONTINUED TO MY OFFICE. THIS IS WAS A VERY SCARY INCIDENT, THANKFULLY I WAS THE ONLY ONE IN MY VEHICLE TODAY; MY GRANDSON IS SOMETIMES WITH ME. I AM ALSO THANKFUL THAT I WAS IN THE RIGHT LANE, SO I WAS ABLE TO COAST INTO THE PARKING LOT. *TR
NHTSA ODI #10264196
40,000 miles · Mar 15, 2009
Electrical System
ON MY 2005 FORD EXPEDITION I HAVE GOTTEN AN ALERT OF "CHECK ELECTRONIC THROTTLE SYSTEM". ON TWO OCCASIONS WHEN THIS ALERT HAS SOUNDED, THE VEHICLE HAS DIED OUT IN THE MIDDLE OF TRAVEL AND I HAD TO GET TO THE SIDE OF THE ROADWAY TO RESTART. ON TWO OTHER OCCASIONS WHEN THIS ALERT HAS SOUNDED, THE VEHICLE DID NOT DIE BUT I WAS NO…
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ON MY 2005 FORD EXPEDITION I HAVE GOTTEN AN ALERT OF "CHECK ELECTRONIC THROTTLE SYSTEM". ON TWO OCCASIONS WHEN THIS ALERT HAS SOUNDED, THE VEHICLE HAS DIED OUT IN THE MIDDLE OF TRAVEL AND I HAD TO GET TO THE SIDE OF THE ROADWAY TO RESTART. ON TWO OTHER OCCASIONS WHEN THIS ALERT HAS SOUNDED, THE VEHICLE DID NOT DIE BUT I WAS NOT ABLE TO ACCELERATE. I HAD TO STOP AND RESTART THE VEHICLE. THIS IS VERY DANGEROUS WHEN YOU ARE TRAVELING DOWN THE ROADWAY AND YOUR CAR EITHER DIES OUT OR LOSSES POWER. AFTER THE SECOND OCCURANCE I TOOK IT INTO THE DEALERSHIP AND WAS TOLD THAT THEY FOUND NOTHING WHEN HOOKED UP TO THE COMPUTER. THEY COULD DO NOTHING. THE VEHICLE RUNS FINE OTHER THAN THIS. THERE IS NO WARNING WHATSOEVER THAT THIS IS GOING TO OCCUR. *TR
NHTSA ODI #10261906
Mileage unknown · Mar 2, 2009
Electrical System
WHILE DRIVING, CHECK ENGINE THROTTLE CONTROL LIGHT COMES ON. THE CAR ESSENTIALLY SHUTS DOWN - LOSES ACCELERATION, POWER STEERING, ETC. THIS HAS HAPPENED THREE TIMES...DECEMBER 10, 2008, FEBRUARY 23, 2009, AND MARCH 2, 2009. THE CAR WILL START AGAIN IF YOU TURN IT OFF AND RE-START IT. THIS CAN BE EXTREMELY DANGEROUS IF IT HAPPENS…
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WHILE DRIVING, CHECK ENGINE THROTTLE CONTROL LIGHT COMES ON. THE CAR ESSENTIALLY SHUTS DOWN - LOSES ACCELERATION, POWER STEERING, ETC. THIS HAS HAPPENED THREE TIMES...DECEMBER 10, 2008, FEBRUARY 23, 2009, AND MARCH 2, 2009. THE CAR WILL START AGAIN IF YOU TURN IT OFF AND RE-START IT. THIS CAN BE EXTREMELY DANGEROUS IF IT HAPPENS AT A POINT WHERE IT'S HARD TO PULL OVER. AFTER READING MESSAGE BOARDS, IT SEEMS TO BE A FAIRLY COMMON PROBLEM IN 2005 EXPEDITIONS. *TR
NHTSA ODI #10260501
62,000 miles · Feb 9, 2009
Electrical System
I WAS DRIVING ON THE FREEWAY AT 65MPH AND THE "CHECK ELECTRONIC THROTTLE CONTROL" LIGHT CAME ON AND THEN MY VEHICLE ENGINE SHUT OFF. I HAD TO PULL OVER WITH NO POWER AND LITTLE ABILITY TO TURN BEFORE VEHICLE WOULD RESTART. IT HAS DONE THIS NOW THREE TIMES. I HAVE RESEARCHED THE COST FOR REPAIRS BUT DUE TO THE HIGH EXPENSE ($5…
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I WAS DRIVING ON THE FREEWAY AT 65MPH AND THE "CHECK ELECTRONIC THROTTLE CONTROL" LIGHT CAME ON AND THEN MY VEHICLE ENGINE SHUT OFF. I HAD TO PULL OVER WITH NO POWER AND LITTLE ABILITY TO TURN BEFORE VEHICLE WOULD RESTART. IT HAS DONE THIS NOW THREE TIMES. I HAVE RESEARCHED THE COST FOR REPAIRS BUT DUE TO THE HIGH EXPENSE ($500) I AM NOT ABLE AT THIS TIME TO FIX. *TR
NHTSA ODI #10258037
75,000 miles · Feb 5, 2009
Electrical System
I WAS DRIVING ABOUT 70MPH WHEN THE MESSAGE CENTER TONE SOUNDED AND THE MESSAGE READ "CHECK THROTTLE CONTROL". THE ENGINE CONTINUED TO RUN, HOWEVER, THE ACCELERATOR BECAME INOPERABLE. IT SEEMS AS IF A LOT OF 05 EXPEDITION OWNERS ARE HAVING THE SAME PROBLEM. THIS IS JUST WAY TO DANGEROUS TO DRIVE WITH THIS ISSUE. I NEVER DRIVE IN…
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I WAS DRIVING ABOUT 70MPH WHEN THE MESSAGE CENTER TONE SOUNDED AND THE MESSAGE READ "CHECK THROTTLE CONTROL". THE ENGINE CONTINUED TO RUN, HOWEVER, THE ACCELERATOR BECAME INOPERABLE. IT SEEMS AS IF A LOT OF 05 EXPEDITION OWNERS ARE HAVING THE SAME PROBLEM. THIS IS JUST WAY TO DANGEROUS TO DRIVE WITH THIS ISSUE. I NEVER DRIVE IN THE MIDDLE LANE ON HIGHWAYS NOW FOR FEAR THAT THIS COULD HAPPEN AT ANY TIME. *TR
NHTSA ODI #10257553
85,000 miles · Feb 1, 2009
Electrical System
WHILE DRIVING THE VEHICLE WILL HAVE NOT HAVE ANY THROTTLE RESPONSE AND "CHECK ELECTRONIC THROTTLE COMPONENT" SHOWS ON DASH. AFTER PULLING TO THE SIDE OF THE ROAD, OR COASTING INTO SOMEONE'S DRIVE-WAY ON A CURVEY ROAD, TURN THE IGNITION OFF AND SIT FOR A FEW MINUTES AND RESTART ENGINE AND IS FINE. HAS OCCURRED 3 TIMES NOW, ALL 3 …
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WHILE DRIVING THE VEHICLE WILL HAVE NOT HAVE ANY THROTTLE RESPONSE AND "CHECK ELECTRONIC THROTTLE COMPONENT" SHOWS ON DASH. AFTER PULLING TO THE SIDE OF THE ROAD, OR COASTING INTO SOMEONE'S DRIVE-WAY ON A CURVEY ROAD, TURN THE IGNITION OFF AND SIT FOR A FEW MINUTES AND RESTART ENGINE AND IS FINE. HAS OCCURRED 3 TIMES NOW, ALL 3 AT SPEEDS LESS THAN 45 MPH. TOOK THE VEHICLE TO FORD DEALERSHIP WHERE THEY CHARGED ME $75 TO TELL ME THE BATTERY NEEDED TO BE REPLACED BECAUSE THAT IS ALL THE CODES THAT THEY CAME UP WITH. THEN I WOULD HAVE TO RETURN THE VEHICLE TO HAVE IT CHECKED AGAIN. ON MY DESCRIPTION OF SERVICE CODES P-1867-2F, B-1317-2F, B1318-2F, B2477-60, B2486-20, B1318-20, U1900-20, P0121-FF, P2104-FF, P2112FF, B1318FF, WERE ALL FOUND. *TR
NHTSA ODI #10257081
50,000 miles · Jan 13, 2009
Electrical System
ELECTRONIC THROTTLE CONTROL LIGHT, I WAS DRIVING ABOUT 50MPH WHEN THE CAR SLOWED DOWN TO A STOP AND THE GAS PEDAL WOULD NOT WORK. THE CAR WAS RUNNING AND ROLLING, BUT I COULD NOT ACCELERATE. (SCARY) *TR
NHTSA ODI #10254869
Mileage unknown · Dec 1, 2008
Electrical SystemFire
2005 FORD EXPEDITION CAR FIRE LOST NINE MONTHS OF PAYMENTS CARS SEATS WALLET EASY UP CANOPIES ETC. *TR
NHTSA ODI #10250345
24,000 miles · Oct 10, 2008
Electrical SystemFuel System, GasolineInterior Lighting
I BOUGHT MY 2005 FORD EXPEDITION IN MARCH 2007 WITH 21K MILES ON IT. I HAVE HAD TO REPLACE 2 DIFFERENT INJECTORS IN 16 MONTHS BECAUSE THE VEHICLE WILL START CUTTING BACK AND ACTING LIKE IT WANTS TO CUT OFF WHEN IT STOPS AT A LIGHT . THE MOST RECENT REPLACEMENT CAME WHEN I DROVE IT 5 MILES FROM HOME AND IT JERKED CONTINUOUSLY T…
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I BOUGHT MY 2005 FORD EXPEDITION IN MARCH 2007 WITH 21K MILES ON IT. I HAVE HAD TO REPLACE 2 DIFFERENT INJECTORS IN 16 MONTHS BECAUSE THE VEHICLE WILL START CUTTING BACK AND ACTING LIKE IT WANTS TO CUT OFF WHEN IT STOPS AT A LIGHT . THE MOST RECENT REPLACEMENT CAME WHEN I DROVE IT 5 MILES FROM HOME AND IT JERKED CONTINUOUSLY THE ENTIRE INSIDE OF THE VEHICLE SMELLED LIKE GAS VERY STRONGLY AS WELL AS THE EXHAUST. THE TRUCK STAYS PARKED MOST OF THE TIME BECAUSE IM TOO SCARED TO DRIVE IT AND ITS A GAS HOG!!!!!! THE REPLACEMENT OF THE INJECTORS ARE NOT CHEAP!!!! THE INSIDE LIGHTS WILL COME ON AND GO OFF AT ANYTIME FOR NO REASON. I TAP THE BRAKES AND THEY COME ON, I ROLL THE WINDOW UP OR DOWN AND THEY COME ON. I HAVE ALSO HAD TO REPLACE THE BATTERY DUE TO THIS HAPPENING EVEN WHEN THE TRUCK HAS BEEN PARKED FOR HOURS. I HAVE REPLACED THE OXYGEN SENSOR AND A COLI PACK. ITS NEVER ENDING AND I FEEL LIKE I SHOULD NOT HAVE TO CONTINUE TO REPLACE THESE THINGS WHEN I AM OBVIOUSLY NOT THE ONLY ONE WITH THIS PROBLEM. FORD NEEDS TO STEP UP AND TAKE RESPONSIBILITY FOR THEIR CRAPPY PRODUCTS. I HAVE 5 MORE YEARS @ $515 PER MONTH TO PAY FOR THIS PIECE OF CRAP!!!!!!!!!!!! *TR
NHTSA ODI #10245098
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
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