NHTSA owner reports · September 18, 2026 snapshot.
Fuel System, Gasoline complaints
36 reportsClear category filter112,925 miles · May 7, 2014
Fuel System, Gasoline
DRIVING UP A SMALL INCLINE AND THE VEHICLE LOST POWER. I HAD ELECTRICAL POWER JUST NO FUEL GETTING TO THE ENGINE. I WAS ABLE TO PULL OFF TO THE SIDE OF THE ROAD. THE FUEL TANK WAS JUST BELOW A 1/4 TANK. ADD A GALLON OF GAS AND TRIED TO RESTART THE CAR. IT WOULD NOT RESTART. CALLED FOR THE TOW TRUCK TO TAKE TO THE GARAGE. …
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DRIVING UP A SMALL INCLINE AND THE VEHICLE LOST POWER. I HAD ELECTRICAL POWER JUST NO FUEL GETTING TO THE ENGINE. I WAS ABLE TO PULL OFF TO THE SIDE OF THE ROAD. THE FUEL TANK WAS JUST BELOW A 1/4 TANK. ADD A GALLON OF GAS AND TRIED TO RESTART THE CAR. IT WOULD NOT RESTART. CALLED FOR THE TOW TRUCK TO TAKE TO THE GARAGE. THE GARAGE HAD TO DROP THE FUEL TANK AND TOLD ME THE FUEL PUMP CONTROL MODULE WAS BAD. THEY HANDED ME THE MODULE UPON PICKING UP MY VEHICLE AND I CAN TELL YOU WHY THE MODULE WENT BAD. IT HAS A HOLE IN IT FROM CORROSION. I HAVE SAID MODULE IF ANYONE FROM FORD OR NHTSA WOULD LIKE TO EXAMINE THE MODULE. *TR
NHTSA ODI #10587112
77,000 miles · Mar 2, 2014
Electrical SystemFuel System, GasolineVehicle Speed Control
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
NHTSA ODI #10566665
112,550 miles · Jan 24, 2014
Engine And Engine CoolingFuel System, Gasoline
I WAS DRIVING MY 2005 FORD EXPEDITION EDDIE BAUER EDITION WHEN I STARTED TO MAKE A TURN. SUDDENLY THE VEHICLE STOPPED MOVING AND AN INDICATOR LIGHT STATING "ENGINE FAIL SAFE MODE" CAME ON. DURING THE TURN, A VEHICLE WAS COMING TOWARD ME AND I BARELY HAD ENOUGH TIME TO GET MY VEHICLE OUT OF THE LANE BEFORE I GOT HIT. I HAD TO STO…
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I WAS DRIVING MY 2005 FORD EXPEDITION EDDIE BAUER EDITION WHEN I STARTED TO MAKE A TURN. SUDDENLY THE VEHICLE STOPPED MOVING AND AN INDICATOR LIGHT STATING "ENGINE FAIL SAFE MODE" CAME ON. DURING THE TURN, A VEHICLE WAS COMING TOWARD ME AND I BARELY HAD ENOUGH TIME TO GET MY VEHICLE OUT OF THE LANE BEFORE I GOT HIT. I HAD TO STOP MY VEHICLE, PUT IT IN PARK (WHILE SITTING ON THE ROADWAY), SHUT IT OFF, AND RESTART IT BEFORE I COULD MOVE AGAIN. IT RAN FINE FOR A COUPLE OF DAYS AND THEN IT HAPPENED TO ME AGAIN WHILE DRIVING. THIS IS A VERY DANGEROUS SITUATION THAT SHOULD BE LOOKED INTO AND AFTER CHECKING THE INTERNET IT SEEMS THERE ARE LOTS OF PEOPLE WITH THE SAME EXPERIENCES. I TOOK MY VEHICLE TO THE SHOP AND THEY TOLD ME IT WAS THE THROTTLE BODY. AFTER SPENDING $409.00 (BECAUSE OF COURSE IT WAS NOT COVERED BY MY WARRANTY) TO REPAIR IT HOPEFULLY THE PROBLEM MAY BE FIXED. I FIGURED SPENDING THE MONEY WAS BETTER THAN THE OPTION OF POSSIBLY GETTING IN A SERIOUS ACCIDENT AND BEING KILLED IF THE PROBLEM WAS NOT FIXED. SOMEBODY NEEDS TO LOOK INTO THIS PROBLEM WITH THE VEHICLE AND MAKE FORD RESPONSIBLE FOR COSTS SINCE IT IS OBVIOUSLY A DEFECT IN THE VEHICLE. *TR
NHTSA ODI #10561395
74,000 miles · Jun 18, 2013
Fuel System, Gasoline
TL* THE CONTACT OWNS A 2007 FORD EXPEDITION. THE CONTACT STATED THAT THE VEHICLE FAILED TO START. THE VEHICLE WAS TOWED TO THE DEALER WHERE IT WAS ADVISED THAT THE FUEL PUMP HAD FAILED. THE CONTACT WAS INFORMED BY THE DEALER THAT THE REPAIR WOULD TAKE THREE MONTHS BECAUSE THE FUEL PUMP WAS ON BACK ORDER AND THERE WAS NO AFTER MA…
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TL* THE CONTACT OWNS A 2007 FORD EXPEDITION. THE CONTACT STATED THAT THE VEHICLE FAILED TO START. THE VEHICLE WAS TOWED TO THE DEALER WHERE IT WAS ADVISED THAT THE FUEL PUMP HAD FAILED. THE CONTACT WAS INFORMED BY THE DEALER THAT THE REPAIR WOULD TAKE THREE MONTHS BECAUSE THE FUEL PUMP WAS ON BACK ORDER AND THERE WAS NO AFTER MARKET FUEL PUMP THAT WOULD WORK ON THE 2005 MODEL YEAR. THE FAILURE AND THE CURRENT MILEAGES WERE 74,000 *TR
NHTSA ODI #10520419
45,000 miles · Apr 29, 2012
Engine And Engine CoolingFuel System, Gasoline
ENGINE STOPS RUNNING AT DIFFERENT SPEEDS. SYSTEM DISPLAYS A CHECK ELECTRONIC THROTTLE CONTROL ERROR. THIS IS VERY DANGEROUS. *TR
NHTSA ODI #10456808
67,000 miles · Feb 2, 2012
Electrical SystemFuel System, Gasoline
VEHICLE HAS BEEN STALLING FOR ALMOST A YEAR. VEHICLE SHUT OFF ON BUSY HIGHWAY AND TOWED TO NEARBY REPAIR SHOP. MECHANIC FOUND FUEL PUMP CONTROL MODULE COMPLETELY CORRODED FROM BEHIND AND CIRCUIT BOARD EXPOSED TO MOISTURE. THE FPCM FRIED AND SHORTED OUT ONE LEG OF THE FUEL PUMP. BOTH PIECES HAD TO BE REPLACED. NEW FPCM INSTALLE…
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VEHICLE HAS BEEN STALLING FOR ALMOST A YEAR. VEHICLE SHUT OFF ON BUSY HIGHWAY AND TOWED TO NEARBY REPAIR SHOP. MECHANIC FOUND FUEL PUMP CONTROL MODULE COMPLETELY CORRODED FROM BEHIND AND CIRCUIT BOARD EXPOSED TO MOISTURE. THE FPCM FRIED AND SHORTED OUT ONE LEG OF THE FUEL PUMP. BOTH PIECES HAD TO BE REPLACED. NEW FPCM INSTALLED WAS OBVIOUSLY REDESIGNED SO MODULE WOULD NOT SUFFER THIS FLAW AGAIN. I AM FINDING AN ALARMING AMOUNT OF COMPLAINTS ON THE INTERNET OF FORD EXPEDITION OWNER EXPERIENCING THE EXACT SAME PROBLEMS UNDER MORE DANGEROUS CONDITIONS. *KB
NHTSA ODI #10446313
Mileage unknown · Jan 29, 2012
Fuel System, Gasoline
VEHICLE STOPED RUNNING ON FLAT LEVEL READ AT 65 MILES PER HOUR.VEHICLE WOULD NOT RESTART. VEHICLE HAD BEEN STALLING PRIOR. MECHANIC CANT PINPOINT PROBLEM BUT FEELS FUEL PUMP, FUEL PUMP MODULE, FUES BOX MALFUNCTION ARE THE CAUSE. TO MANY STORIES OF THIS PROBLEM SURFACING. MY FAMILY IN DANGER WITH VEHICLE STOPPED ON MAJOR HIGHWAY,…
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VEHICLE STOPED RUNNING ON FLAT LEVEL READ AT 65 MILES PER HOUR.VEHICLE WOULD NOT RESTART. VEHICLE HAD BEEN STALLING PRIOR. MECHANIC CANT PINPOINT PROBLEM BUT FEELS FUEL PUMP, FUEL PUMP MODULE, FUES BOX MALFUNCTION ARE THE CAUSE. TO MANY STORIES OF THIS PROBLEM SURFACING. MY FAMILY IN DANGER WITH VEHICLE STOPPED ON MAJOR HIGHWAY, CAUSED BY A WELL KNOWN PROBLEM FORD IS AWARE OF. *TT
NHTSA ODI #10445741
50,000 miles · Jan 11, 2012
Fuel System, Gasoline
2005 FORD EXPEDITION HAS EXPERIENCED APPROXIMATELY 5 EPISODES WHERE IT HAS STALLED WITH NO NOTICE OR PRIOR INDICATION OF A PROBLEM. THE PROBLEM STARTED AROUND 50K MILES AND HAPPENED MOST RECENTLY AS ABOUT 120K MILES. ON AT LEAST 2 OCCASIONS THE CENTER DASH INDICATED ENGINE FAILSAFE MODE. EACH TIME, THE TRUCK COULD BE IMMEDIATE…
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2005 FORD EXPEDITION HAS EXPERIENCED APPROXIMATELY 5 EPISODES WHERE IT HAS STALLED WITH NO NOTICE OR PRIOR INDICATION OF A PROBLEM. THE PROBLEM STARTED AROUND 50K MILES AND HAPPENED MOST RECENTLY AS ABOUT 120K MILES. ON AT LEAST 2 OCCASIONS THE CENTER DASH INDICATED ENGINE FAILSAFE MODE. EACH TIME, THE TRUCK COULD BE IMMEDIATELY RESTARTED AND WOULD OPERATE NORMALLY. THE ONLY COMMON CIRCUMSTANCE IS THAT THE TRUCK WAS COASTING TO A LOWER SPEED AT THE TIME OF THE FAILURE. NO CODES ARE RECORDED, SO NO TROUBLESHOOTING CAN BE PERFORMED. REPLACED THE THROTTLE POSITION SENSOR, BUT FAILURE HAS OCCURRED TWICE SINCE. THE NEXT STEP IS TO REPLACE THE THROTTLE BODY ASSEMBLY. *TR
NHTSA ODI #10443463
103,000 miles · May 4, 2011
Fuel System, Gasoline
TL*THE CONTACT OWNS A 2005 FORD EXPEDITION. THE CONTACT STATED THE FUEL PUMP DRIVER MODULE FAILED. THE CONTACT STATED WHILE DRIVING 65 MPH THE VEHICLE STALLED WITHOUT WARNING. THE FUEL PUMP DRIVER MODULE WAS LOCATED IN THE REAR OF THE VEHICLE NEAR THE FUEL TANK. THE FAILURE DESTROYED THE FUEL PUMP AND BLEW THE 15 AMP FUSE THAT A…
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TL*THE CONTACT OWNS A 2005 FORD EXPEDITION. THE CONTACT STATED THE FUEL PUMP DRIVER MODULE FAILED. THE CONTACT STATED WHILE DRIVING 65 MPH THE VEHICLE STALLED WITHOUT WARNING. THE FUEL PUMP DRIVER MODULE WAS LOCATED IN THE REAR OF THE VEHICLE NEAR THE FUEL TANK. THE FAILURE DESTROYED THE FUEL PUMP AND BLEW THE 15 AMP FUSE THAT ALLOWS THE FUEL PUMP TO FUNCTION. THE DEALER INFORMED THE CONTACT THAT THE PART WAS CURRENTLY ON BACK ORDER. THE FAILURE AND CURRENT MILEAGES WERE 103,000.
NHTSA ODI #10398906
66,859 miles · Apr 14, 2011
Fuel System, Gasoline
TL* THE CONTACT OWNS A 2005 FORD EXPEDITION. THE CONTACT WAS DRIVING APPROXIMATELY 10 MPH WHEN THE ENGINE STALLED WITHOUT PRIOR WARNING. THE ENGINE FAILED TO RESTART AND THE VEHICLE WAS TOWED AN AUTHORIZED DEALER WHERE THE FUEL PUMP DRIVER MODULE WAS REPLACED. THE FAILURE MILEAGE WAS 66,859. UPDATED 05/05/11*LJ THE CONSUMER STA…
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TL* THE CONTACT OWNS A 2005 FORD EXPEDITION. THE CONTACT WAS DRIVING APPROXIMATELY 10 MPH WHEN THE ENGINE STALLED WITHOUT PRIOR WARNING. THE ENGINE FAILED TO RESTART AND THE VEHICLE WAS TOWED AN AUTHORIZED DEALER WHERE THE FUEL PUMP DRIVER MODULE WAS REPLACED. THE FAILURE MILEAGE WAS 66,859. UPDATED 05/05/11*LJ THE CONSUMER STATED WHEN THE ENGINE FAILED, HE LOST POWER STEERING. HE WAS ON STEEP HILL AND WAS ABLE TO STOP BY PLACING THE TRUCK INTO PARK AND APPLYING THE EMERGENCY BRAKE. UPDATED 07/01/11
NHTSA ODI #10395916
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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