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2005 Ford Expedition

Owner reports · Recalls · Investigations

More warning signs than most Expedition years

Owner complaints for the 2005 Ford Expedition are substantially higher than the model-year median of 155.

About this comparison →

When problems were reported

Mileage at the reported incident

289 reports with mileage · 26 unknown

NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.

What to inspect

Issues worth paying extra attention to based on owner reports.

  • Electrical System. Review the 76 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Vehicle Speed Control. Review the 66 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Engine. Review the 57 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

20 crash reports6 fire reports10 injury reports

Vehicle Speed Control complaints

66 reports
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76,000 miles · Jan 22, 2012
Engine And Engine CoolingVehicle Speed Control

I WAS DRIVING MY CAR WHEN ALL OF A SUDDEN THE ACCELERATOR IS NOT RESPONDING AND SO I NEED TO COAST THE CAR TO THE CURVE. I CALLED THE DEALER AND SO MY CAR WAS STILL UNDER MY EXTENDED WARRANTY AND SO I TOOK THE CAR IN AND I WAS TOLD THAT THEY REPLACED THE PART THIS WAS IN MARCH 2009, IT IS NOW JANUARY 21, 2012 AND I HAD THE SAME…

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I WAS DRIVING MY CAR WHEN ALL OF A SUDDEN THE ACCELERATOR IS NOT RESPONDING AND SO I NEED TO COAST THE CAR TO THE CURVE. I CALLED THE DEALER AND SO MY CAR WAS STILL UNDER MY EXTENDED WARRANTY AND SO I TOOK THE CAR IN AND I WAS TOLD THAT THEY REPLACED THE PART THIS WAS IN MARCH 2009, IT IS NOW JANUARY 21, 2012 AND I HAD THE SAME PROBLEM. THE MESSAGE BOARD READS, CHECK ELECTRONIC THROTTLE SYSTEM. *TR

NHTSA ODI #10444763

92,000 miles · Dec 14, 2011
Vehicle Speed Control

AT 45 MPH I LOST THROTTLE CONTROL AND WARNING LIGHT CAME ON INDICATING "ELECTRONIC THROTTLE CONTROL". I DRIFTED TO THE SIDE OF THE ROAD, PUT IN PARK AND TURNED OFF ENGINE. I RESTARTED AND EVERYTHING WAS FINE AND WARNING LIGHT WAS GONE. HAS BEEN FINE FOR THE PAST COUPLE OF WEEKS. READING EVERYBODY'S CONCERNS ON THIS ISSUE MAKES M…

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AT 45 MPH I LOST THROTTLE CONTROL AND WARNING LIGHT CAME ON INDICATING "ELECTRONIC THROTTLE CONTROL". I DRIFTED TO THE SIDE OF THE ROAD, PUT IN PARK AND TURNED OFF ENGINE. I RESTARTED AND EVERYTHING WAS FINE AND WARNING LIGHT WAS GONE. HAS BEEN FINE FOR THE PAST COUPLE OF WEEKS. READING EVERYBODY'S CONCERNS ON THIS ISSUE MAKES ME WONDER IF THERE REALLY IS A FIX FOR THIS. I CERTAINLY DON'T TRUST THE DEALERS......WHAT'S UP FORD??? *TR

NHTSA ODI #10439987

134,500 miles · Oct 31, 2011
Electrical SystemVehicle Speed Control

TRAVELING ALONG CONGESTED CITY STREET DURING MORNING RUSH AND VEHICLE LOOSES ALL POWER. INSTRUMENT CLUSTER LIGHTS ARE ALL ON. MESSAGE SAY "CHECK ELECTRONIC THROTTLE" I WAS ABLE TO TURN THE VEHICLE OFF AND BACK ON TWICE BEFORE THE ERROR CLEARED. I HAVE AN APPOINTMENT AT THE DEALERSHIP IN THE MORNING. BUT THESE OTHER REPORTS DON'…

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TRAVELING ALONG CONGESTED CITY STREET DURING MORNING RUSH AND VEHICLE LOOSES ALL POWER. INSTRUMENT CLUSTER LIGHTS ARE ALL ON. MESSAGE SAY "CHECK ELECTRONIC THROTTLE" I WAS ABLE TO TURN THE VEHICLE OFF AND BACK ON TWICE BEFORE THE ERROR CLEARED. I HAVE AN APPOINTMENT AT THE DEALERSHIP IN THE MORNING. BUT THESE OTHER REPORTS DON'T GIVE ME MUCH HOPE. AND I JUST PAID OFF THE NOTE LAST WEEK. *TR

NHTSA ODI #10433681

Mileage unknown · Sep 19, 2011
Engine And Engine CoolingPower TrainVehicle Speed Control

WHILE DRIVING AT 60MPH ON US 85 N THE ENGINE LIGHT CAME ON WITH A MESSAGE "CHECK ELECTRONIC THROTTLE CONTROL" THE SPEED BEGAN TO DROP AND I COULD NOT ACCELERATE. I BEGAN TO MERGE TO THE RIGHT TO THE EMERGENCY LANE. I TURNED OFF THE ENGINE AND STARTED AGAIN. THEN I DROVE THE VEHICLE HOME. IT WAS A VERY SCARY EXPERIENCE I COU…

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WHILE DRIVING AT 60MPH ON US 85 N THE ENGINE LIGHT CAME ON WITH A MESSAGE "CHECK ELECTRONIC THROTTLE CONTROL" THE SPEED BEGAN TO DROP AND I COULD NOT ACCELERATE. I BEGAN TO MERGE TO THE RIGHT TO THE EMERGENCY LANE. I TURNED OFF THE ENGINE AND STARTED AGAIN. THEN I DROVE THE VEHICLE HOME. IT WAS A VERY SCARY EXPERIENCE I COULD HAVE BEEN IN AN ACCIDENT. IT WAS VERY DANGEROUS. THIS SHOULD BE A RECALL PROBLEM. *KB

NHTSA ODI #10426374

90,000 miles · Aug 15, 2011
Power TrainVehicle Speed Control

2005 FORD EXPEDITION EDDIE BAUER, 90,000 MILES. (VEHICLE MANUFACTURED IN 2004.) WHILE BEING DRIVEN AT HIGHWAY SPEED THROTTLE STUCK IN FULLY DEPRESSED POSITION AFTER BEING ENGAGED FOR A ROUTINE PASS OF ANOTHER VEHICLE. VEHICLE WAS NOTED TO ACCELERATE. ACCELERATOR PEDAL COULD NOT BE RETURNED TO NON-DEPRESSED STATE WHEN FORCE …

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2005 FORD EXPEDITION EDDIE BAUER, 90,000 MILES. (VEHICLE MANUFACTURED IN 2004.) WHILE BEING DRIVEN AT HIGHWAY SPEED THROTTLE STUCK IN FULLY DEPRESSED POSITION AFTER BEING ENGAGED FOR A ROUTINE PASS OF ANOTHER VEHICLE. VEHICLE WAS NOTED TO ACCELERATE. ACCELERATOR PEDAL COULD NOT BE RETURNED TO NON-DEPRESSED STATE WHEN FORCE APPLIED. BRAKES APPLIED FORCEFULLY, VEHICLE WAS UNABLE TO BE SLOWED OR BROUGHT TO A STOP. STRONG SMELL OF "BURNING" BRAKE PADS WAS NOTED. ATTEMPTED TO SHIFT VEHICLE INTO AUTOMATIC TRANSMISSION POSITION OF NEUTRAL. NO CHANGE IN ENGINE SPEED NOTED. TRANSMISSION THEN SHIFTED INTO REVERSE. VEHICLE WHEELS LOCKED UP AND VEHICLE SKIDDED APPROXIMATELY 100 - 150 FEET BEFORE COMING TO A STOP. ANTILOCK SYSTEM AND OTHER SYSTEMS DID NOT ACTIVATE. AFTER COMING TO A STOP, THROTTLE PEDAL WAS INSPECTED. NO INTERIOR INTERFERENCE FROM FLOOR MATS OR OTHER MATERIALS NOTED. OPERATOR IS 100% CERTAIN AS A RESULT OF "REAL-TIME" VISUAL CONFIRMATION, THAT ACCELERATOR AND BRAKE PEDALS WERE NOT MISTAKENLY ENGAGED OR DUALLY ENGAGED. CRUISE CONTROL WAS NOT ENGAGED. VEHICLE HAS BEEN SERVICED AND MAINTAINED REGULARLY AND WITH PRECISION AND DETAIL. VEHICLE WAS INSPECTED BY AN INDEPENDENT MECHANIC IMMEDIATELY POST THE INCIDENT. THROTTLE BODY FOUND TO BE FOULED AND DIRTY. INDEPENDENT MECHANIC IS REASONABLY CERTAIN THAT DIRTY THROTTLE BODY IS MOST LIKELY CAUSE OF THIS EVENT. INDEPENDENT MECHANIC HAS PERSONAL KNOWLEDGE AND EXPERIENCE OF SIMILAR THROTTLE BODY FAILURES PRODUCING SIMILAR EVENTS AS HAS BEEN DESCRIBED ABOVE. THIS VEHICLE HAS HAD OTHER PREMATURE FAILURES, INCLUDING (1) NEED FOR TRANSMISSION AND TRANSFER CASE TO BE REBUILT AT 28,000 MILES; (2) FAILURE OF POWER DRIVER'S SEAT TO MOVE ON ITS TRACK AT 25,000 MILES; (3) PREMATURE CAM PHASER FAILURE AND REBUILD AT APPROXIMATELY 35,000 MILES. *TR

NHTSA ODI #10419439

70,000 miles · Apr 14, 2011
Electrical SystemVehicle Speed Control

TL* THE CONTACT OWNS A 2005 FORD EXPEDITION. WHILE DRIVING AT VARIOUS SPEEDS, THE CONTACT HEARD A BEEPING NOISE AND THEN NOTICED THAT THE CHECK ELECTRONIC THROTTLE WARNING LIGHT WAS ILLUMINATED AS THE VEHICLE LOST POWER. THE FAILURE RECURRED ON FOUR SEPARATE OCCASIONS. THE VEHICLE WAS TOWED TO A PRIVATE MECHANIC WHO ADVISED THE …

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TL* THE CONTACT OWNS A 2005 FORD EXPEDITION. WHILE DRIVING AT VARIOUS SPEEDS, THE CONTACT HEARD A BEEPING NOISE AND THEN NOTICED THAT THE CHECK ELECTRONIC THROTTLE WARNING LIGHT WAS ILLUMINATED AS THE VEHICLE LOST POWER. THE FAILURE RECURRED ON FOUR SEPARATE OCCASIONS. THE VEHICLE WAS TOWED TO A PRIVATE MECHANIC WHO ADVISED THE CONTACT THAT THE ELECTRONIC CONTROL MODULE HAD FAILED. HE REMOVED THE BATTERY TERMINAL, RESET THE COMPUTER, CLEARED ALL CODES, REPLACED THE THROTTLE POSITION CENSOR, AND CLEANED THE THROTTLE BODY. THE DEALER WAS NOTIFIED OF THE PREVIOUS FAILURES AND DID NOT OFFER ANY ASSISTANCE. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE CURRENT MILEAGE WAS 110,000 AND THE FAILURE MILEAGE WAS 70,000. THE VIN WAS UNAVAILABLE. UPDATED 04/25/11 *BF THE CONSUMER STATED THE PROBLEM HAPPENED FOR A SECOND TIME. UPDATED 06/20/11

NHTSA ODI #10395906

73,000 miles · Mar 24, 2011
Vehicle Speed Control

TL* THE CONTACT OWNS A 2005 FORD EXPEDITION. THE CONTACT STATED WHILE DRIVING 35 MPH, THE ELECTRONIC THROTTLE CONTROL WARNING LIGHT WAS ILLUMINATED AND THE VEHICLE IMMEDIATELY STALLED. THE CONTACT STATED THAT THE FAILURE WOULD RECUR WHEN DRIVING ANY SPEED. THE VEHICLE WOULD RESTART IMMEDIATELY AND DRIVE AS NORMAL. THE DEALER WA…

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TL* THE CONTACT OWNS A 2005 FORD EXPEDITION. THE CONTACT STATED WHILE DRIVING 35 MPH, THE ELECTRONIC THROTTLE CONTROL WARNING LIGHT WAS ILLUMINATED AND THE VEHICLE IMMEDIATELY STALLED. THE CONTACT STATED THAT THE FAILURE WOULD RECUR WHEN DRIVING ANY SPEED. THE VEHICLE WOULD RESTART IMMEDIATELY AND DRIVE AS NORMAL. THE DEALER WAS CONTACTED AND STATED THAT THE THROTTLE BODY WOULD POSSIBLY NEED REPLACING AT A COST OF $600. THERE WERE NO RECALLS OR WARRANTIES FOR THE FAILURE. THE MANUFACTURER WAS NOT CONTACTED. THE FAILURE MILEAGE WAS 73,000 AND THE CURRENT MILEAGE WAS 98,000.

NHTSA ODI #10392731

92,000 miles · Feb 7, 2011
Vehicle Speed Control

TL*THE CONTACT OWNS A 2005 FORD EXPEDITION EDDIE BAUER EDITION(NA). WHILE DRIVING 10-20 MPH, THE ELECTRONIC THROTTLE CONTROL LIGHT ILLUMINATED ON THE INSTRUMENT PANEL. THE VEHICLE STALLED AND THE CONTACT COASTED THE VEHICLE TO THE SIDE OF THE ROAD. AFTER A FEW MINUTES, THE VEHICLE WAS RESTARTED AND FUNCTIONED PROPERLY. THE LIGHT…

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TL*THE CONTACT OWNS A 2005 FORD EXPEDITION EDDIE BAUER EDITION(NA). WHILE DRIVING 10-20 MPH, THE ELECTRONIC THROTTLE CONTROL LIGHT ILLUMINATED ON THE INSTRUMENT PANEL. THE VEHICLE STALLED AND THE CONTACT COASTED THE VEHICLE TO THE SIDE OF THE ROAD. AFTER A FEW MINUTES, THE VEHICLE WAS RESTARTED AND FUNCTIONED PROPERLY. THE LIGHT ON THE INSTRUMENT PANEL TURNED OFF AS WELL. THE VEHICLE WAS TAKEN TO A LOCAL REPAIR SHOP WHERE THE CONTACT WAS INFORMED THAT THE THROTTLE SENSOR NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED. THE FAILURE OCCURRED AGAIN. THE VEHICLE HAD NOT BEEN REPAIRED. THE FAILURE MILEAGE WAS 92,000 AND THE CURRENT MILEAGE WAS 94,000.

NHTSA ODI #10381010

80,000 miles · Jan 21, 2011
Vehicle Speed Control

TL*THE CONTACT OWNS A 2005 FORD EXPEDITION. WHILE DRIVING APPROXIMATELY 50 MPH THE VEHICLE STALLED. AFTER APPROXIMATELY THREE MINUTES THE CONTACT WAS ABLE TO RESTART THE VEHICLE AND CONTINUE DRIVING. THE CONTACT ALSO STATED THAT THE FAILURE OCCURRED INTERMITTENTLY IN THE PAST WHILE DRIVING AT ANY SPEED. THE FAILURE AND CURRENT …

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TL*THE CONTACT OWNS A 2005 FORD EXPEDITION. WHILE DRIVING APPROXIMATELY 50 MPH THE VEHICLE STALLED. AFTER APPROXIMATELY THREE MINUTES THE CONTACT WAS ABLE TO RESTART THE VEHICLE AND CONTINUE DRIVING. THE CONTACT ALSO STATED THAT THE FAILURE OCCURRED INTERMITTENTLY IN THE PAST WHILE DRIVING AT ANY SPEED. THE FAILURE AND CURRENT MILEAGES WERE 80,000. UPDATED 02/11/11 *BF THE TPS SENSOR WAS REPLACED. HOWEVER, THE PROBLEM RETURNED. UPDATED 03/11/11

NHTSA ODI #10378152

71,000 miles · Jan 21, 2011
Electrical SystemFuel System, GasolineVehicle Speed Control

THIS IS THE FIFTH INCIDENT REGARDING THIS VEHICLE. IN EACH CASE, THE CAR WAS TRAVELING AT A NORMAL RATE OF SPEED UNDER ORDINARY TRAFFIC CONDITIONS. WITHOUT WARNING, THE CAR EITHER LOST POWER AND SHUT OFF SUDDENLY OR LOST THE ABILITY TO ACCELERATE AND SLOWED TO A STOP. IN EACH CASE THE DASHBOARD MESSAGE CENTER WARNING "CHECK ELEC…

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THIS IS THE FIFTH INCIDENT REGARDING THIS VEHICLE. IN EACH CASE, THE CAR WAS TRAVELING AT A NORMAL RATE OF SPEED UNDER ORDINARY TRAFFIC CONDITIONS. WITHOUT WARNING, THE CAR EITHER LOST POWER AND SHUT OFF SUDDENLY OR LOST THE ABILITY TO ACCELERATE AND SLOWED TO A STOP. IN EACH CASE THE DASHBOARD MESSAGE CENTER WARNING "CHECK ELECTRONIC THROTTLE CONTROL" (OR SOMETHING SIMILAR) APPEARED. IN EACH CASE THE DRIVER TURNED THE IGNITION SWITCH TO THE OFF POSITION, WAITED SEVERAL MINUTES, AND THEN STARTED THE CAR. THE WARNING MESSAGE NO LONGER APPEARED AND THE CAR RAN FINE WITHOUT ANY FURTHER IMMEDIATE INCIDENT. IN THIS PARTICULAR CASE (INCIDENT #5), THE CAR WAS TRAVELING AT APPROXIMATELY 25 MPH SOUTH ON 14TH ST NW IN WASHINGTON, DC, WHEN THE CAR LOST THE ABILITY TO ACCELERATE, AND THE "CHECK ELECTRONIC THROTTLE CONTROL" WARNING APPEARED IN THE DASHBOARD MESSAGE CENTER. DUE TO TRAFFIC AND STREET PARKING CONDITIONS, THE DRIVER WAS UNABLE TO MOVE THE CAR OUT OF THE ACTIVE TRAFFIC LANE, THEREBY TEMPORARILY BLOCKING TRAFFIC. THE DRIVER TURNED OFF THE IGNITION, WAITED APPROXIMATELY 3 MINUTES, AND THEN STARTED THE CAR. THE DASHBOARD WARNING LIGHT WAS NO LONGER ILLUMINATED, AND THE CAR WAS ABLE TO ACCELERATE NORMALLY. INCIDENTS SIMILAR TO THIS HAVE BEEN REPORTED ON VARIOUS WEBSITES. *TR

NHTSA ODI #10378107

Official recalls

0

No recalls in this snapshot.

Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗

NHTSA investigations

1

PE08070 · 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