NHTSA owner reports · September 18, 2026 snapshot.
Engine And Engine Cooling complaints
47 reportsClear category filter70,000 miles · Oct 1, 2009
Engine And Engine Cooling
WHILE TRAVELING AT AROUND 50-60 MPH, THE VEHICLE LOST POWER AND I PULLED OVER INTO A PARKING LOT. THE DASH EXHIBITED A SYMBOL IMPLYING THE "ELECTRONIC THROTTLE" WAS MALFUNCTIONING. THIS IS QUITE DANGEROUS BECAUSE IT OCCURS WHILE DRIVING DOWN THE STREET WITH NO PRIOR WARNING. DO NOT KNOW YET HOW MUCH REPAIR WILL BE AS IT OCCU…
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WHILE TRAVELING AT AROUND 50-60 MPH, THE VEHICLE LOST POWER AND I PULLED OVER INTO A PARKING LOT. THE DASH EXHIBITED A SYMBOL IMPLYING THE "ELECTRONIC THROTTLE" WAS MALFUNCTIONING. THIS IS QUITE DANGEROUS BECAUSE IT OCCURS WHILE DRIVING DOWN THE STREET WITH NO PRIOR WARNING. DO NOT KNOW YET HOW MUCH REPAIR WILL BE AS IT OCCURRED TODAY. NOTICED ON WEBSITE COMMENTS SECTION THAT THIS HAPPENS FREQUENTLY WITH THE 2005 FORD EXPEDITION. WANT TO KNOW WHAT FORD IS DOING ABOUT THIS. *TR
NHTSA ODI #10285932
36,000 miles · Oct 1, 2009
Engine And Engine Cooling
2005 EXPEDITION HAS SEVERE ENGINE TICKING PROBLEM (SOUNDS LIKE A DIESEL) ORIGINAL COMPLAINT WAS BEFORE WARRANTY EXPIRED TOLD BY DEALER THAT IT WAS THE "3 VALVE MOTOR NOISE". WHEN IT GOT WORSE AT AROUND 37K MILES (1K) OUT OF WARRANTY DEALER THEN TELLS ME THAT THERE HAS BEEN A TSB ISSUED (TSB 06-4-7 ORIGINAL VERSION WAS ACTUALLY I…
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2005 EXPEDITION HAS SEVERE ENGINE TICKING PROBLEM (SOUNDS LIKE A DIESEL) ORIGINAL COMPLAINT WAS BEFORE WARRANTY EXPIRED TOLD BY DEALER THAT IT WAS THE "3 VALVE MOTOR NOISE". WHEN IT GOT WORSE AT AROUND 37K MILES (1K) OUT OF WARRANTY DEALER THEN TELLS ME THAT THERE HAS BEEN A TSB ISSUED (TSB 06-4-7 ORIGINAL VERSION WAS ACTUALLY ISSUED SHORTLY AFTER THE TRUCK WAS BUILT) IT IS THE CAM PHASERS AND VALVE LASH ADJUSTERS AND IT WILL BE $3000 TO REPAIR AND NOW NOT COVERED UNDER WARRANTY. I HAVE REPEATEDLY WORKED WITH THE DEALER AND FORD CUSTOMER CARE TO RESOLVE ISSUE THE LAST PERSON AT CUSTOMER CARE TOLD ME "ITS YOUR PROBLEM" JUST BEFORE HANGING UP ON ME. THIS AFTER A SIMILAR PULLING TEETH EPISODE TO GET THEM TO FIX THE KNOWN CORROSION PROBLEM THAT THEY HAD AND DENIED BEFORE I FOUND A TSB ABOUT THAT TOO, I NOW HAVE ANOTHER LARGE RUST SPOT ON MY BACK DOOR THAT THE WILL NOT FIX EITHER. ALL OF THIS AFTER I PAID $4000 TO GET RID OF THE LINCOLN LS THAT I OWNED THAT THEY COULD NOT KEEP RUNNING AFTER DUMPING THOUSANDS OF DOLLARS INTO A COP PROBLEM THAT WAS EVENTUALLY COVERED UNDER A CUSTOMER CARE PROGRAM. I SURE DID NOT GET ANY MONEY BACK ON THAT. SOMEONE HAS TO WAKE SOMEONE OVER AT FORD UP AND GET THEM TO FIX THIS GARBAGE THEY HAVE BEEN TURNING OUT.. *TR
NHTSA ODI #10285892
69,890 miles · Jun 19, 2009
Engine And Engine Cooling
I RECENTLY TOOK MY 2005 FORD EXPEDITION FOR A TUNE-UP AT A LOCAL SHOP. THE OWNER OF THE SHOP TOLD ME THAT THE SPARK PLUG IN CYLINDER #4 BROKE AND IS STUCK IN THE ENGINE. THE SAFEST WAY TO REMEDY THE PROBLEM IS TO TAKE THE ENGINE HEAD OFF TO TAKE OUT THE BROKEN SPARK PLUG. I DID A RESEARCH ON THE INTERNET AND FOUND THAT FORD'S …
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I RECENTLY TOOK MY 2005 FORD EXPEDITION FOR A TUNE-UP AT A LOCAL SHOP. THE OWNER OF THE SHOP TOLD ME THAT THE SPARK PLUG IN CYLINDER #4 BROKE AND IS STUCK IN THE ENGINE. THE SAFEST WAY TO REMEDY THE PROBLEM IS TO TAKE THE ENGINE HEAD OFF TO TAKE OUT THE BROKEN SPARK PLUG. I DID A RESEARCH ON THE INTERNET AND FOUND THAT FORD'S DESIGN OF THE SPARK PLUGS CAUSES THE THREAD TO SEPARATE FROM THE SPARK PLUG ITSELF LEADING TO THE BREAKING OF THE PLUGS. THERE ARE ALSO INSTANCES WHERE THE SPARK PLUG IS EJECTED FROM THE ENGINE. I TRIED TO FILE A COMPLAINT WITH FORD MOTOR COMPANY; HOWEVER, THEY REFUSED TO CALL IT A DEFECT IN THEIR SPARK PLUG DESIGNS. *TR
NHTSA ODI #10274319
65,120 miles · May 6, 2009
Engine And Engine Cooling
WHILE DRIVING ON TWO SEPARATE OCCASIONS SUDDENLY THE CHECK ENGINE THROTTLE CONTROL LIGHT HAS COME ONE. UPON SAFELY PULLING OVER AND RESTARTING THE CAR THE LIGHT GOES OFF AND APPARENTLY THE THROTTLE RESETS. THE DANGER IS THAT WHEN THE LIGHT COMES ON THE CAR GOES INTO IDLE ONLY MODE. NO ACCELERATING, ETC. THERE IS NO WARNING THAT …
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WHILE DRIVING ON TWO SEPARATE OCCASIONS SUDDENLY THE CHECK ENGINE THROTTLE CONTROL LIGHT HAS COME ONE. UPON SAFELY PULLING OVER AND RESTARTING THE CAR THE LIGHT GOES OFF AND APPARENTLY THE THROTTLE RESETS. THE DANGER IS THAT WHEN THE LIGHT COMES ON THE CAR GOES INTO IDLE ONLY MODE. NO ACCELERATING, ETC. THERE IS NO WARNING THAT THIS IS GOING TO HAPPEN AND NO OTHER REMEDY. THE FIRST TIME I WAS IN A CARPOOL SETTING IDLING. THE SECOND TIME I HAD JUST GOTTEN OFF THE INTERSTATE AND WAS ABLE TO PULL INTO A SHOPPING CENTER. THIS IS A MAJOR SAFETY CONCERN IF IT HAPPENS ON THE INTERSTATE. I HAVE TAKEN THE CAR IN TO HAVE A DIAGNOSTIC EVALUATION AND THERE IS NO KNOWN CAUSE OF THE FAILURE. AFTER READING 100S OF SIMILAR COMPLAINTS ONLINE IT IS APPARENT THIS IS A PROBLEM FOR THE MAKE AND MODEL THAT NEEDS TO BE INVESTIGATED. *TR
NHTSA ODI #10267863
35,000 miles · May 6, 2009
Engine And Engine Cooling
2005 FORD EXPEDITION WITH ERROR MESSAGE OF 'CHECK ELECTRONIC THROTTLE CONTROL'. IT HAS HAPPENED 5 TIMES NOW. ENGINE, STEERING AND BRAKING STOP WORKING INSTANTLY. I HAVE TO SHUT TRUCK OFF TO RESTART. ALL TIMES IT HAS HAPPENED WHILE GOING 60-70 MILES AN HOUR ON HIGHWAY. FORD HAS CHARGED ME OVER $1200 TO THIS DAY FOR FIXES, BU…
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2005 FORD EXPEDITION WITH ERROR MESSAGE OF 'CHECK ELECTRONIC THROTTLE CONTROL'. IT HAS HAPPENED 5 TIMES NOW. ENGINE, STEERING AND BRAKING STOP WORKING INSTANTLY. I HAVE TO SHUT TRUCK OFF TO RESTART. ALL TIMES IT HAS HAPPENED WHILE GOING 60-70 MILES AN HOUR ON HIGHWAY. FORD HAS CHARGED ME OVER $1200 TO THIS DAY FOR FIXES, BUT NOTHING HAS FIXED THE PROBLEM. THEY ALSO HAVE NO ANSWER AS TO WHY IT KEEPS RECURRING. WHEN THEY HOOK IT UP TO THE COMPUTER, THEY SAY THERE ARE NO ERROR CODES. *TR
NHTSA ODI #10267820
75,000 miles · Apr 15, 2009
Engine And Engine Cooling
WHILE DRIVING THE CAR ON THE HIGHWAY WITH CHILDREN IN THE VEHICLE, THE ENGINE LIGHT CAME ON, MESSAGE CAME ON ABOUT ELECTRONIC THROTTLE CONTROL , AND THE VEHICLE LOST ALL FUNCTIONS OF STEERING, BRAKING, AND ACCELERATING. THERE WERE NO WARNINGS BEFORE THIS HAPPENED. AFTER TAKING IT TO THE FORD DEALER TODAY, I SEE ON THE INTERNE…
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WHILE DRIVING THE CAR ON THE HIGHWAY WITH CHILDREN IN THE VEHICLE, THE ENGINE LIGHT CAME ON, MESSAGE CAME ON ABOUT ELECTRONIC THROTTLE CONTROL , AND THE VEHICLE LOST ALL FUNCTIONS OF STEERING, BRAKING, AND ACCELERATING. THERE WERE NO WARNINGS BEFORE THIS HAPPENED. AFTER TAKING IT TO THE FORD DEALER TODAY, I SEE ON THE INTERNET THAT MANY MANY MANY FAMILIES ARE HAVING THIS SAME PROBLEM WITH 2005 FORD EXPEDITIONS. SEEING AS THE PROBLEM CREATES AN IMMEDIATE SAFETY CONCERN FOR NOT ONLY THE FAMILY IN THE 2005 FORD EXPEDITION, BUT ALL THE FAMILIES TRAVELING AROUND THE 2005 FORD EXPEDITION... I FEEL LIKE THE SAFETY BOARD SHOULD LOOK INTO THIS AS A POTENTIAL RECALL FOR 2005 FORD EXPEDITIONS. THANKFULLY MY FAMILY IS SAFE TODAY...BUT SOMEONE'S FAMILY MAY NOT BE SO LUCKY. *TR
NHTSA ODI #10265518
69,900 miles · Mar 18, 2009
Engine And Engine Cooling
WHILE DRIVING MY 2005 FORD EXPEDITION (4 SEPARATE INCIDENTS) DOWN THE ROAD, A WARNING MESSAGE APPEARS ON THE MESSAGE CENTER TO "CHECK ELECTRONIC THROTTLE CONTROL". THE VEHICLE LOSES ALL ACCELERATION, ACCELERATOR DOES NOT WORK, I HAVE TO COAST TO THE SIDE OF THE ROAD, RESTART THE VEHICLE THEN IT RUNS FINE. VERY DANGEROUS, FORTU…
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WHILE DRIVING MY 2005 FORD EXPEDITION (4 SEPARATE INCIDENTS) DOWN THE ROAD, A WARNING MESSAGE APPEARS ON THE MESSAGE CENTER TO "CHECK ELECTRONIC THROTTLE CONTROL". THE VEHICLE LOSES ALL ACCELERATION, ACCELERATOR DOES NOT WORK, I HAVE TO COAST TO THE SIDE OF THE ROAD, RESTART THE VEHICLE THEN IT RUNS FINE. VERY DANGEROUS, FORTUNATELY NO ONE HURT AND NO DAMAGE. BUT IF THIS WOULD HAPPEN ON AN INTERSTATE IN THE LEFT LANE IN HEAVY TRAFFIC...?? VERY SCARY SITUATION! ACCORDING TO MY MECHANIC AND A FORD DEALERSHIP, THEY CANNOT FIND A CAUSE AND NO FAULT CODES COME UP IN COMPUTER. SUGGEST POSSIBLE FIX OF REPLACING THE THROTTLE BODY FOR ABOUT $700-800, WITH NO RESPONSIBILITY FROM FORD. *TR
NHTSA ODI #10262260
90,000 miles · Mar 11, 2009
Engine And Engine Cooling
CAR KEEPS DIES IN TRAFFIC ALMOST EVERYDAY AND THE ELECTRONIC THROTTLE CONTROL LIGHT KEEPS COMING ON . FORD WANTS $800 TO FIX. WITH THIS SAFETY ISSUE, I BELIEVE THERE SHOULD SOME SORT OF ACTION FORD SHOULD TAKE AND FIX THE PROBLEM SINCE IT IS ALWAYS HAPPENING TO THIS YEAR AND MODEL SO OFTEN. *TR
NHTSA ODI #10261589
80,000 miles · Mar 5, 2009
Engine And Engine Cooling
2005 EXPEDITION EDDIE BAUER 4X4 - GOT A THROTTLE CONTROL ERROR MESSAGE, WAS TRAVELING AT ABOUT 55 MPH IN MORNING RUSH HOUR TRAFFIC ON A MAJOR HIGHWAY (DC/BALT) AND WAS LUCKY NOT TO GET SLAMMED INTO. VEHICLE ENGINE DIED, EVERYTHING ELSE WORKED. I SHUT IT ALL DOWN, TURNED THE KEY AND FIRED IT BACK UP AND IT IS RUNNING FINE AGAIN.…
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2005 EXPEDITION EDDIE BAUER 4X4 - GOT A THROTTLE CONTROL ERROR MESSAGE, WAS TRAVELING AT ABOUT 55 MPH IN MORNING RUSH HOUR TRAFFIC ON A MAJOR HIGHWAY (DC/BALT) AND WAS LUCKY NOT TO GET SLAMMED INTO. VEHICLE ENGINE DIED, EVERYTHING ELSE WORKED. I SHUT IT ALL DOWN, TURNED THE KEY AND FIRED IT BACK UP AND IT IS RUNNING FINE AGAIN. IT DID THE SAME THING ABOUT 5 MONTHS AGO. FORD SHOWS NO RECALLS. MY VEHICLE HAS BEEN PUT ON A COMPUTER AND NO ERROR CODES CAME UP. THE COMPUTER IS REPORTING NOTHING. THIS IS VERY DANGEROUS AND OTHER PEOPLE ARE REPORTING THE SAME PROBLEM... HTTP://WWW.FIXYA.COM/CARS/T1061679-ELECTRONIC_THROTTLE_CONTROL_LIGHT_CAME#SAMEPROBLEMCONTINUED. *TR
NHTSA ODI #10260829
68,000 miles · Feb 23, 2009
Engine And Engine Cooling
TL*THE CONTACT OWNS A 2005 FORD EXPEDITION. WHILE DRIVING 50 MPH, THE VEHICLE BEGAN TO FAIL AND THE CONTACT NOTICED THAT HER SPEED REDUCED TO 30 MPH. SHE WAS ABLE TO APPLY THE BRAKES AND SLOW THE VEHICLE DOWN. THE VEHICLE THEN SHUT OFF AND TOOK THREE ATTEMPTS TO RESTART. THE DEALER DETERMINED THAT THE THROTTLE BODY DISENGAGE…
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TL*THE CONTACT OWNS A 2005 FORD EXPEDITION. WHILE DRIVING 50 MPH, THE VEHICLE BEGAN TO FAIL AND THE CONTACT NOTICED THAT HER SPEED REDUCED TO 30 MPH. SHE WAS ABLE TO APPLY THE BRAKES AND SLOW THE VEHICLE DOWN. THE VEHICLE THEN SHUT OFF AND TOOK THREE ATTEMPTS TO RESTART. THE DEALER DETERMINED THAT THE THROTTLE BODY DISENGAGED AND THE VEHICLE WAS REPAIRED AT THE COST OF $700. THE CONTACT IS IN THE PROCESS OF NOTIFYING THE MANUFACTURER. THE VIN WAS UNAVAILABLE. THE FAILURE MILEAGE WAS 68,000.
NHTSA ODI #10259697
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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