NHTSA owner reports · September 18, 2026 snapshot.
Fuel System, Other complaints
9 reportsClear category filter83,123 miles · Apr 16, 2011
Fuel System, Other
ME HUSBAND AND I OWN A 2005 FORD EXPEDITION XLT (V8 5.4L). THE TRUCK HAS CUT OFF ON US SEVERAL TIMES IN THE LAST TO WEEKS, WITHOUT WARNING! IT HAS EVEN CUT OFF ON US ON THE HIGHWAY. WE WERE TRAVELING 55MPH. WE HAVE FOUR SMALL CHILDREN THAT TRAVEL WITH US CONSTANTLY. I CONSIDER THIS TO BE A LIFE THREATENING DEFECT. MY HUSBAN…
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ME HUSBAND AND I OWN A 2005 FORD EXPEDITION XLT (V8 5.4L). THE TRUCK HAS CUT OFF ON US SEVERAL TIMES IN THE LAST TO WEEKS, WITHOUT WARNING! IT HAS EVEN CUT OFF ON US ON THE HIGHWAY. WE WERE TRAVELING 55MPH. WE HAVE FOUR SMALL CHILDREN THAT TRAVEL WITH US CONSTANTLY. I CONSIDER THIS TO BE A LIFE THREATENING DEFECT. MY HUSBAND TOOK THE TRUCK TO A MECHANIC, THINKING OH WE JUST NEED A TUNE UP. TWO OF THE SPARK PLUGS BROKE OFF INTO THE MOTOR HEAD. WE ENDED UP SPENDING $800 BUCKS TO HAVE IT REPAIRED AND $150 BUCKS ON A VAN RENTAL. IN MY OPINION FORD SHOULD HANDLE THIS SITUATION AS SOON AS POSSIBLE. IT IS A LIFE THREATENING DEFECT. WE ARE THANKFUL THAT WE MADE IT OFF OF THE HIGHWAY SAFELY THAT DAY. BUT WHAT IF ANOTHER FAMILY HAS THE SAME PROBLEM....AND THEY ARE NOT SO LUCKY? I GUESS FORD WILL THEN ISSUE A RECALL AND EXTEND THEIR MOST SINCERE APOLOGIES. *TR
NHTSA ODI #10396532
38,000 miles · Dec 24, 2010
Electrical SystemEquipmentFuel System, Other
STOPPED AT A TRAFFIC LIGHT INTERSECTION TO MAKE A RIGHT TURN. WHILE I WAS MAKING THE RIGHT TURN ABOUT 5 MPH, THE 2005 FORD EXPEDITION STALLED AND ALL THE LIGHTS WENT ON. I WAITED FOR ABOUT 10 SECONDS TO TURN ON THE CAR. THE CAR STARTED. I STOPPED 5 MINUTES LATER TO STOP THE ENGINE TO SEE IF EVERYTHING WAS OK. IT TOOK TWO TR…
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STOPPED AT A TRAFFIC LIGHT INTERSECTION TO MAKE A RIGHT TURN. WHILE I WAS MAKING THE RIGHT TURN ABOUT 5 MPH, THE 2005 FORD EXPEDITION STALLED AND ALL THE LIGHTS WENT ON. I WAITED FOR ABOUT 10 SECONDS TO TURN ON THE CAR. THE CAR STARTED. I STOPPED 5 MINUTES LATER TO STOP THE ENGINE TO SEE IF EVERYTHING WAS OK. IT TOOK TWO TRIES TO START THE ENGINE. I TOOK IT TO A FORD DEALER THE NEXT DAY TO GET IT INSPECTED. THEY CLAIM IT WAS THE "THROTTLE POSITION SENSOR". I GOT THAT REPLACED FOR ~$340.00. *TR
NHTSA ODI #10372365
87,000 miles · Aug 26, 2010
Fuel System, Other
1.2005 FORD EXPEDITION AUGUST 8,2010: AROUND 12:45PM I STARTED MY CAR UP TO RUN TO MCDONALD'S TWO MINUTES AWAY FROM MY WORK. AS I PULLED OUT OF MCDONALD'S THE CAR STARTED TO SLOW DOWN AND WOULD NOT ACCELERATE. I THOUGHT IT WAS MY GAS SO I PULLED INTO EXXON DOWN THE STREET TO FILL UP ON GAS. I PUT $15 OF GAS INTO THE TANK. WHEN I…
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1.2005 FORD EXPEDITION AUGUST 8,2010: AROUND 12:45PM I STARTED MY CAR UP TO RUN TO MCDONALD'S TWO MINUTES AWAY FROM MY WORK. AS I PULLED OUT OF MCDONALD'S THE CAR STARTED TO SLOW DOWN AND WOULD NOT ACCELERATE. I THOUGHT IT WAS MY GAS SO I PULLED INTO EXXON DOWN THE STREET TO FILL UP ON GAS. I PUT $15 OF GAS INTO THE TANK. WHEN I STARTED TO CAR UP IT IMMEDIATELY STARTED SHAKING VIGOROUSLY AND A STRONG SMELL OF GAS AND CLOUDY FUMES CAME FROM MY EXHAUST PIPE. I HAD TO GO BACK TO WORK SO I DROVE THE TWO MILES WHILE TO CAR STRONGLY SHOOK AND THE EXHAUST PIPE WAS PRODUCING A CLOUD OF SMOKE THAT SMELLED HEAVILY OF GAS. I GOT TO WORK AND CALLED MY HUSBAND. I TURNED OFF THE CAR AND CHECKED MY OIL. I ATTEMPTED TO TURN ON MY CAR AGAIN AND WAS NOT ABLE TO GET MY CAR TO START AGAIN THAT DAY. AT 7PM I ATTEMPTED TO TURN MY CAR ON AGAIN AND IT JUST MADE A LOUD SCREECHY SOUND AND WOULD NOT TURN ON. 2.BECAUSE CAR WOULD NOT START WE CALLED HARRY'S TOWING TO BE TOWED TO A AUTO SHOP NEAREST TO OUR HOME. OUR CAR NEVER BEFORE HAS HAD ANY PROBLEMS AT ALL. 3. WE ASKED THE MECHANIC TO LOOK AT THE CAR AND IDENTIFY THE PROBLEM. WHEN HE CALLED US BACK HE SAID THE FUEL INJECTOR WAS THE PROBLEM AND HE AT THAT TIME HAD REPLACED IT ALREADY AND ADVISED US TO TAKE THE CAR TO FORD DUE TO THE FACT THE HE SAID THE MOTOR WAS DEAD AS WELL. WE THEN HAD THE CAR TOWED TO FORD IN FRANKLIN KENTUCKY. THEY IDENTIFIED THE PROBLEM AS THE FUEL INJECTOR AND THAT THE MOTOR FAILURE WAS DUE TO FUEL INJECTOR PROBLEMS. THE HEADQUARTERS OF FORD SAID WE ARE NOW NOT COVERED UNDER THE EXTENDED WARRANTY DUE TO THE FACT THAT WE TOOK THE CAR TO SOMEONE BESIDES FORD. *TR
NHTSA ODI #10352177
41,000 miles · May 11, 2010
Fuel System, Other
2005 FORD EXPEDITION STOPPED RUNNING WHILE DRIVING AT 40 MPH IN HEAVY TRAFFIC. VEHICLE WOULD NOT RESTART. IT APPEARS TO BE A FUEL PUMP PROBLEM. ONLY 40,000 MILES ON THIS VEHICLE. NONE OF THE DASH BOARD LIGHT INDICATORS CAME ON. *TR
NHTSA ODI #10330000
61,000 miles · Mar 1, 2010
Fuel System, Other
INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6) 2005 FORD EXPEDITION [XXX] ENGINE SHUTS DOWN WHILE TRAVELING 50 MPH, FAILSAFE MODE INDICATOR LIGHT COMES ON. THIS HAS HAPPENED TWICE IN THE LAST MONTH. IT IS A HUGE LIFE SAFETY ISSUE WHEN YOU THINK YOU HAVE CONTROL OF THE VEHICLE AND Y…
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INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6) 2005 FORD EXPEDITION [XXX] ENGINE SHUTS DOWN WHILE TRAVELING 50 MPH, FAILSAFE MODE INDICATOR LIGHT COMES ON. THIS HAS HAPPENED TWICE IN THE LAST MONTH. IT IS A HUGE LIFE SAFETY ISSUE WHEN YOU THINK YOU HAVE CONTROL OF THE VEHICLE AND YOU ACTUALLY DO NOT. I HAVE 4 CHILDREN I PUT INTO THIS VEHICLE AND I FEAR OUR SAFETY. I HAVE BEEN TOLD TODAY BY FORD THAT THE THROTTLE BODY IS FAULTY AND NEEDS TO BE REPLACED. THIS IS A PART THAT SHOULD NEVER HAVE TO BE REPLACED! CLEANED MAYBE BUT NEVER REPLACED. I HAVE 61, 000 MILES ON THE VEHICLE AND THIS PART SHOULD NOT BE BAD. I WILL BE REPLACING IT THIS WEEK, BUT I FEEL THAT FORD DOES NOT WANT TO ADDRESS THIS MATTER AS I SPOKE TO THE SERVICE MANAGER,[XXX]AT AL PACKER FORD WEST 561-790-1100 AND ALSO FORD CORPORATE OFFICE AT 800-241-3673 AND ALL THEY SAID THEY WOULD DO IS DOCUMENT THE PROBLEM. HOW MANY PEOPLE WILL CRASH OR DIE BEFORE SAFETY IS TAKEN SERIOUSLY? WHY DO DEALERSHIPS NOT TAKE RESPONSIBILITY FOR FAULTY PARTS. THIS IS A VERY FRIGHTENING EXPERIENCE FOR BOTH MYSELF AND MY CHILDREN AND IT HAS BEEN DOCUMENTED AND VERBALLY EXPRESSED TO SEVERAL PEOPLE NOW. I WOULD LIKE TO SEE ACTION TAKEN BEFORE SOMEONE DIES. *TR
NHTSA ODI #10315082
127,000 miles · Nov 6, 2009
Engine And Engine CoolingFuel System, Other
2005 FORD EXPEDITION 5.4 ENGINE, MISFIRING 3&5 CYLINDER. ROUGH IDLE. CAR HAS 127,000 MILES AND SINCE WE HAVE HAD IT I HAD ISSUES WITH IT IDLING IN PARK AND ALMOST AT TIMES WANTING TO STALL. ENGINE HAS ON MORE THAN 3 OCCASIONS WHILE DRIVING 60-70 MPH ON THE HIGHWAY BECOME UN RESPONSIVE WHILE DRIVING. ENGINE WOULD RUN BUT NO ACCEL…
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2005 FORD EXPEDITION 5.4 ENGINE, MISFIRING 3&5 CYLINDER. ROUGH IDLE. CAR HAS 127,000 MILES AND SINCE WE HAVE HAD IT I HAD ISSUES WITH IT IDLING IN PARK AND ALMOST AT TIMES WANTING TO STALL. ENGINE HAS ON MORE THAN 3 OCCASIONS WHILE DRIVING 60-70 MPH ON THE HIGHWAY BECOME UN RESPONSIVE WHILE DRIVING. ENGINE WOULD RUN BUT NO ACCELERATION WHEN THE GAS PEDAL WAS PUSHED; IT WAS LIKE THE CAR WAS RUNNING IN NEUTRAL. INDICATOR LIGHT CAME ON SHOWING "ENGINE FAILURE". PULLED OFF THE ROAD AND RESTARTED CAR AND THEN IT RAN FINE AGAIN. FORD SVC DEPT. COULD NOT REPLICATE THE SITUATION WHEN I TOOK IT TO THEM, SO IT WAS NEVER REPAIRED. (CLEARLY THERE IS A FAULTY PROBLEM) CURRENTLY CAR IS IN THE SHOP REPLACING ALL 8 SPARK PLUGS, COILS AND BOOTS. MECHANIC INDICATED A LOT OF CARBON BUILDUP IN THROTTLE BODY. (SEEMS TO ME POSSIBLY SOME OTHER FAULTY COMPONENT COULD BE WHY I'M HAVING TO SPEND $800 TO FULLY REPAIR MY CAR). *TR
NHTSA ODI #10291248
64,721 miles · Oct 30, 2009
Engine And Engine CoolingFuel System, Other
2005 FORD EXPEDITION DISPLAYED "ELECTRONIC THROTTLE CONTROL FAILURE" MESSAGE AND ENGINE ABRUPTLY QUIT AT HIGH SPEED IN TRAFFIC ON A CURVED ROAD RESULTING IN A SIMULTANEOUS LOSS OF POWER STEERING AND POWER BRAKES. THIS APPEAR TO BE A COMMON PROBLEM FOR WHICH THERE HAS BEEN NO SAFETY RECALL. A FAILURE LIKE THIS WITH NO MECHANICA…
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2005 FORD EXPEDITION DISPLAYED "ELECTRONIC THROTTLE CONTROL FAILURE" MESSAGE AND ENGINE ABRUPTLY QUIT AT HIGH SPEED IN TRAFFIC ON A CURVED ROAD RESULTING IN A SIMULTANEOUS LOSS OF POWER STEERING AND POWER BRAKES. THIS APPEAR TO BE A COMMON PROBLEM FOR WHICH THERE HAS BEEN NO SAFETY RECALL. A FAILURE LIKE THIS WITH NO MECHANICAL BACKUP FOR ENGINE THROTTLE CONTROL IS A SERIOUS SAFETY ISSUE. *TR
NHTSA ODI #10290423
70,000 miles · Mar 2, 2009
Fuel System, Other
2005 FORD EXPEDITION - NORMAL DRIVING, COMPLETE LOSS OF DRIVE POWER. COMES UP AS ELECTRONIC THROTTLE. YOU MUST PULL OFF ROAD, TURN VEHICLE OFF, THEN RESTART. THIS IS VERY WIDESPREAD, JUST DO A GOOGLE SEARCH FOR THROTTLE EXPEDITION. IT HAS RECURRED AT VARIOUS TIMES ALWAYS SEEMING TO RESET. FORD WANT $700 TO FIX. *TR
NHTSA ODI #10260491
39,950 miles · Jan 29, 2008
Fuel System, Other
THE VEHICLE LOSES POWER WHILE YOU ARE DRIVING, THERE IS NO WARNING OF ANY TYPE. JUST ALL OF A SUDDEN YOUR TRUCK WON'T MOVE. THIS CAN CAUSE SOMEONE TO REAR END YOUR VEHICLE. *CN
NHTSA ODI #10216363
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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