NHTSA owner reports · September 18, 2026 snapshot.
Engine And Engine Cooling complaints
47 reportsClear category filter114,000 miles · May 18, 2011
Engine And Engine Cooling
WHILE TRAVELING 60-65 MPH, IN THE FAST LINE OF A FOUR LANE INTERSTATE, MY 2005 FORD EXPEDITION SUFFERED ENGINE FAILURE. I WAS ABLE TO SAFELY GET MY CAR OFF THE INTERSTATE WITHOUT HARMING MYSELF OR MY CHILDREN. THE MECHANIC INFORMED US A ROCKER PIN HAD BROKEN AND CAUSED DAMAGE TO A PISTON RESULTING IN THE NEED FOR A NEW ENGINE…
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WHILE TRAVELING 60-65 MPH, IN THE FAST LINE OF A FOUR LANE INTERSTATE, MY 2005 FORD EXPEDITION SUFFERED ENGINE FAILURE. I WAS ABLE TO SAFELY GET MY CAR OFF THE INTERSTATE WITHOUT HARMING MYSELF OR MY CHILDREN. THE MECHANIC INFORMED US A ROCKER PIN HAD BROKEN AND CAUSED DAMAGE TO A PISTON RESULTING IN THE NEED FOR A NEW ENGINE. I AM REPORTING THE INCIDENT TO YOU BECAUSE WHEN WE PICKED UP OUR CAR AT THE SERVICE DEPARTMENT, HAVING HAD THE ENGINE REPLACED, WE WERE TOLD THAT THERE WERE TWO OTHER FORDS (1EXPEDITION AND 1F150) THAT CAME IN AFTER OURS WITH THE SAME ISSUE. *TR
NHTSA ODI #10401528
51,000 miles · May 2, 2011
Engine And Engine Cooling
TL*THE CONTACT OWNS A 2005 FORD EXPEDITION. THE CONTACT STATED WHILE DRIVING 70 MPH THE VEHICLE SUDDENLY SHUT OFF. THE VEHICLE WAS IN LIMP MODE WHEN THE FAILURE OCCURRED. HE DROVE ONTO THE EMERGENCY LANE AND SHUT THE VEHICLE OFF AND THEN RESTARTED IT. THE VEHICLE WORKED FINE AFTER IT WAS RESTARTED. THE CONTACT CALLED THE MANUF…
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TL*THE CONTACT OWNS A 2005 FORD EXPEDITION. THE CONTACT STATED WHILE DRIVING 70 MPH THE VEHICLE SUDDENLY SHUT OFF. THE VEHICLE WAS IN LIMP MODE WHEN THE FAILURE OCCURRED. HE DROVE ONTO THE EMERGENCY LANE AND SHUT THE VEHICLE OFF AND THEN RESTARTED IT. THE VEHICLE WORKED FINE AFTER IT WAS RESTARTED. THE CONTACT CALLED THE MANUFACTURER REGARDING THE ENGINE AND THE MANUFACTURER ADVISED HER TO TAKE THE VEHICLE TO A DEALER FOR DIAGNOSTIC TESTING. THE CONTACT DID NOT TAKE THE VEHICLE TO THE DEALER FOR DIAGNOSTIC TESTING BECAUSE OF THE COST. THE CONTACT STATED THAT THIS WAS A MAJOR SAFETY ISSUE. THE FAILURE MILEAGE WAS 51,000. THE CONSUMER STATED THE THROTTLE CONTROL UNIT MAY BE A SAFETY PROBLEM, CAUSING SUDDEN LOSS OF ENGINE POWER TO THE VEHICLE. THE LIMP HOME MODE IS AT IDLE SPEED. HOWEVER, WITH THE ENGINE SHUT DOWN, THE VEHICLE STILL HAS POWER BRAKE AND STEERING. THE ENGINE SHUT DOWN CAN OCCUR AT ANYTIME AT ANY SPEED. UPDATED 08/18/11
NHTSA ODI #10398519
60,000 miles · Jan 18, 2011
Electrical SystemEngine And Engine CoolingSteering
WHILE TRAVELING 50 MPH ON BUSY STREET CAR POWER FAILED, SHUTTING OFF COMPLETELY INCLUDING LOSS OF POWER STEERING. ENGINE FAILURE LIGHT CAME ON. RESTARTED AFTER THAT AND DROVE FINE. SINCE THEN IT HAS OCCURRED 3 TIMES OVER LAST MONTH. LAST WEEK OCCURRED AT WHEN I WAS ATTEMPTING TO TURN WITH A TURN SIGNAL BUT SHUT OFF BEFORE I …
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WHILE TRAVELING 50 MPH ON BUSY STREET CAR POWER FAILED, SHUTTING OFF COMPLETELY INCLUDING LOSS OF POWER STEERING. ENGINE FAILURE LIGHT CAME ON. RESTARTED AFTER THAT AND DROVE FINE. SINCE THEN IT HAS OCCURRED 3 TIMES OVER LAST MONTH. LAST WEEK OCCURRED AT WHEN I WAS ATTEMPTING TO TURN WITH A TURN SIGNAL BUT SHUT OFF BEFORE I COULD MAKE THE TURN. THIS IS A LIFE THREATENING PROBLEM AND NEEDS TO BE RECALLED. THOUGHT IT HAD TO DO WITH LOW GAS TANK BUT HAD PLENTY OF GAS LAST WEEK. *TR
NHTSA ODI #10377708
113,000 miles · Jan 13, 2011
Engine And Engine Cooling
DRIVING ON FREEWAY IN MY 2005 FORD EXPEDITION, WHEN I LOST POWER AND BRAKES AND THE CHECK ENGINE LIGHT CAME ON. COASTED TO THE SIDE OF FREEWAY. VERY DANGEROUS INCIDENT. *TR
NHTSA ODI #10376547
36,000 miles · Dec 19, 2010
Engine And Engine CoolingSteeringVehicle Speed Control
WHILE DRIVING ON US 95 NORTH THE VEHICLE ALL OF THE SUDDEN STALLED. THIS HAS HAPPENED TWICE BEFORE WHILE DRIVING AT SPEEDS OF 60 AND GREATER ON BUSY INTERSTATES. THE ENGINE JUST STOPS AND THE CAR MUST COAST TO THE SIDE OF THE ROAD AND SIT FOR A FEW MINUTES AND THEN IT WILL START AGAIN AND RUN FINE FOR AT LEAST A WEEK OR TWO. …
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WHILE DRIVING ON US 95 NORTH THE VEHICLE ALL OF THE SUDDEN STALLED. THIS HAS HAPPENED TWICE BEFORE WHILE DRIVING AT SPEEDS OF 60 AND GREATER ON BUSY INTERSTATES. THE ENGINE JUST STOPS AND THE CAR MUST COAST TO THE SIDE OF THE ROAD AND SIT FOR A FEW MINUTES AND THEN IT WILL START AGAIN AND RUN FINE FOR AT LEAST A WEEK OR TWO. RECENTLY THIS HAS BEEN HAPPENING EVERY COUPLE OF MONTHS. THE FIRST INCIDENT WAS IN JAN OF 2010 ON A TRIP FROM MISSOURI TO VIRGINIA. NOW THAT WE LIVE IN VIRGINIA, NEAR DC THIS IS SOMETHING THAT WE FIND VERY DANGEROUS ESPECIALLY WITH FOUR CHILDREN IN THE CAR.
NHTSA ODI #10371673
83,500 miles · Dec 16, 2010
Engine And Engine CoolingPower Train
2005 FORD EXPEDITION LIMITED ~83.5K MILES VEHICLE HAD BEEN DRIVEN ABOUT A HALF HOUR AND THE ENGINE STOPPED WITHOUT WARNING, UNABLE TO ACCELERATE, BRAKE OR STEER. COASTED TO SIDE OF ROAD, SHUT VEHICLE OFF, RESTARTED. TOOK TO DEALERSHIP, UNABLE TO REGISTER CODE HOWEVER I PROVIDED THEM WITH COMMENTS FROM ONLINE SITES POINTING TO TH…
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2005 FORD EXPEDITION LIMITED ~83.5K MILES VEHICLE HAD BEEN DRIVEN ABOUT A HALF HOUR AND THE ENGINE STOPPED WITHOUT WARNING, UNABLE TO ACCELERATE, BRAKE OR STEER. COASTED TO SIDE OF ROAD, SHUT VEHICLE OFF, RESTARTED. TOOK TO DEALERSHIP, UNABLE TO REGISTER CODE HOWEVER I PROVIDED THEM WITH COMMENTS FROM ONLINE SITES POINTING TO THROTTLE CONTROL BODY FAILURE CAUSING ENGINE TO GO INTO FAILSAFE MODE. DEALERSHIP'S FIRST INCLINATION WITHOUT ANY CODES IS TO REPLACE A FUEL SENSOR. DEALERSHIP REFUSED TO ADDRESS THROTTLE CONTROL BODY DESPITE MY SUGGESTION ALONG WITH OTHER VEHICLE OWNER'S INCIDENT REPORTS FROM ONLINE SITES. 8 DAYS LATER WHILE MY HUSBAND WAS DRIVING MYSELF AND FIVE CHILDREN, AFTER ABOUT A HALF HOUR OF DRIVING, HE FOUND HE WAS UNABLE TO ACCELERATE, LOOKED AT THE MESSAGE CENTER AND IT SAID CHECK ELECTRONIC THROTTLE CONTROL AT WHICH TIME HE PUT THE VEHICLE IN NEUTRAL AND WAS ABLE TO RESTART. DEALERSHIPS ARE NOT ADDRESSING THIS ISSUE BECAUSE THE ONBOARD COMPUTER OR SENSORS ARE NOT STORING THESE CODES, THE PROBLEM IS SO FAR INTERMITTENT. THIS PARTICULAR DEALERSHIP DESPITE MY RESEARCH WOULD NOT ADDRESS THE ISSUE. IT ALSO APPEARS FORD IS NOT ACKNOWLEDGING THIS EITHER. SO FAR, I HAVE FOUND ONE INSTANCE ONLINE WHERE THE OWNER OF A 2006 EXPEDITION WAS REIMBURSED FROM FORD FOR THE REPLACEMENT OF THEIR ELECTRONIC THROTTLE CONTROL BODY THEREBY ACKNOWLEDGING SOME SEMBLANCE OF RESPONSIBILITY. THIS NEWER THROTTLE CONTROL BODY IS DIFFERENT THAN THE ORIGINAL, IMPROVED. WHY IS THERE NOT A RECALL OR EVEN A TSB? HOW MANY REPORTS OF THERE OUT THERE, HOW MANY ACCIDENTS, INJURIES, POSSIBLY DEATHS MIGHT BE ATTRIBUTED TO THIS FAILURE? AFTER CONTACTING FORD, WE WILL HAVE THE THROTTLE CONTROL BODY REPLACED. ALSO, IT APPEARS, PEOPLE ARE BEING SUGGESTED TO REPLACE THE SENSOR FIRST ONLY TO HAVE THE PROBLEM OCCUR AGAIN - IT'S NOT THE SENSOR, IT'S THE ACTUAL PART. *TR
NHTSA ODI #10370941
56,000 miles · Nov 30, 2010
Engine And Engine Cooling
TL*THE CONTACT OWNS A 2005 FORD EXPEDITION. WHILE THE CONTACT WAS DRIVING APPROXIMATELY 5 MPH, THE VEHICLE SUDDENLY STOPPED ACCELERATING WITH NO WARNING. THE CONTACT HAD TO TURN THE IGNITION OFF AND ON TO ALLEVIATE THE PROBLEM. THE VEHICLE WAS TAKEN TO A LOCAL REPAIR SHOP BUT THE FAILURE COULD NOT BE DIAGNOSED. THE FAILURE OCCUR…
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TL*THE CONTACT OWNS A 2005 FORD EXPEDITION. WHILE THE CONTACT WAS DRIVING APPROXIMATELY 5 MPH, THE VEHICLE SUDDENLY STOPPED ACCELERATING WITH NO WARNING. THE CONTACT HAD TO TURN THE IGNITION OFF AND ON TO ALLEVIATE THE PROBLEM. THE VEHICLE WAS TAKEN TO A LOCAL REPAIR SHOP BUT THE FAILURE COULD NOT BE DIAGNOSED. THE FAILURE OCCURRED THREE TIMES. THE FAILURE MILEAGE WAS APPROXIMATELY 56,000.
NHTSA ODI #10368389
38,000 miles · Nov 16, 2010
Engine And Engine Cooling
I FILED A COMPLAINT IN OCT (10355191) REQUESTING INFO ON VEHICLE SHUT DOWN. IT HAPPENED AGAIN THIS WEEK WHILE MY WIFE WAS DRIVING TO WORK. *TR
NHTSA ODI #10365913
81,800 miles · Aug 19, 2010
Engine And Engine Cooling
TL* THE CONTACT OWNS A 2005 FORD EXPEDITION. WHILE DRIVING 35 MPH, THE CHECK ENGINE WARNING LIGHT ILLUMINATED AND THE VEHICLE BEGAN TO DRIVE ROUGH. THERE WAS ALSO A LARGE QUANTITY OF SMOKE COMING FROM THE TAIL PIPE. THE VEHICLE WAS TOWED TO A LOCAL REPAIR FACILITY WHERE THE CONTACT WAS INFORMED THAT THE FUEL INJECTOR FAILED. THE…
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TL* THE CONTACT OWNS A 2005 FORD EXPEDITION. WHILE DRIVING 35 MPH, THE CHECK ENGINE WARNING LIGHT ILLUMINATED AND THE VEHICLE BEGAN TO DRIVE ROUGH. THERE WAS ALSO A LARGE QUANTITY OF SMOKE COMING FROM THE TAIL PIPE. THE VEHICLE WAS TOWED TO A LOCAL REPAIR FACILITY WHERE THE CONTACT WAS INFORMED THAT THE FUEL INJECTOR FAILED. THE FUEL INJECTOR WAS REPLACED YET THE FAILURE RECURRED. THE DEALER ADVISED THERE WAS A PROBLEM WITH THE CATALYTIC CONVERTER AND RECOMMENDED REPLACING. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 81,800.
NHTSA ODI #10350519
Mileage unknown · Aug 10, 2010
Engine And Engine Cooling
TL*THE CONTACT OWNS A 2005 FORD EXPEDITION. THE VEHICLE STALLED WHILE DRIVING AT ANY SPEED. WHEN THE VEHICLE STALLS THE STEERING WHEEL ALSO BECOMES VERY STIFF. DURING THE FAILURE A CHECK ENGINE THROTTLE LIGHT ILLUMINATES ON THE DASHBOARD. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER HE WAS INFORMED EITHER THE THROTTLE OR TH…
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TL*THE CONTACT OWNS A 2005 FORD EXPEDITION. THE VEHICLE STALLED WHILE DRIVING AT ANY SPEED. WHEN THE VEHICLE STALLS THE STEERING WHEEL ALSO BECOMES VERY STIFF. DURING THE FAILURE A CHECK ENGINE THROTTLE LIGHT ILLUMINATES ON THE DASHBOARD. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER HE WAS INFORMED EITHER THE THROTTLE OR THE ENGINE NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS UNKNOWN AND THE CURRENT MILEAGE WAS 112,866.
NHTSA ODI #10348513
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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