NHTSA owner reports · September 18, 2026 snapshot.
Vehicle Speed Control complaints
66 reportsClear category filter69,000 miles · Apr 11, 2010
Fuel System, GasolineVehicle Speed Control
2005 FORD EXPEDITION WITHOUT WARNING STALLED WHILE MAKING A RIGHT HAND TURN AT AN INTERSECTION. VEHICLE TAKEN TO DEALERSHIP AND INFORMED ELECTRONIC THROTTLE BODY NEEDED TO BE REPLACED. VEHICLE ONLY HAS 60,000 MILES. INFORMED BY DEALERSHIP REASONS FOR DEFECT UNKNOW. HOWEVER, WE WERE STILL RESPONSIBLE FOR ALL REPAIR COSTS. REV…
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2005 FORD EXPEDITION WITHOUT WARNING STALLED WHILE MAKING A RIGHT HAND TURN AT AN INTERSECTION. VEHICLE TAKEN TO DEALERSHIP AND INFORMED ELECTRONIC THROTTLE BODY NEEDED TO BE REPLACED. VEHICLE ONLY HAS 60,000 MILES. INFORMED BY DEALERSHIP REASONS FOR DEFECT UNKNOW. HOWEVER, WE WERE STILL RESPONSIBLE FOR ALL REPAIR COSTS. REVIEW OF INTERNET INDICATES SEVERAL FORD CUSTOMERS HAVE REPORTED SAME PROBLEM WITH EXACT YEAR AND MAKE OF VEHICLE. *TR
NHTSA ODI #10324936
99,000 miles · Mar 10, 2010
Engine And Engine CoolingVehicle Speed Control
2005 FORD EXPEDITION WITH 90,000 MILES ON IT, DRIVEN IN NORMAL VEHICLE STALLS WHILE DRIVING UNDER NORMAL CONDITIONS, AND THE "CHECK ELECTRONIC THROTTLE CONTROL" MESSAGE COMES ON INFOR SCREEN, THEN ENGINE LIGHT COMES ON. ALMOST RAN INTO DITCH ALONG SIDE OF ROAD LAST TIME WHEN ENGINE STALLED, AS POWER STEERING AND BRAKES SHUT DO…
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2005 FORD EXPEDITION WITH 90,000 MILES ON IT, DRIVEN IN NORMAL VEHICLE STALLS WHILE DRIVING UNDER NORMAL CONDITIONS, AND THE "CHECK ELECTRONIC THROTTLE CONTROL" MESSAGE COMES ON INFOR SCREEN, THEN ENGINE LIGHT COMES ON. ALMOST RAN INTO DITCH ALONG SIDE OF ROAD LAST TIME WHEN ENGINE STALLED, AS POWER STEERING AND BRAKES SHUT DOWN AS WELL. *TR
NHTSA ODI #10318468
70,000 miles · Mar 3, 2010
Fuel System, GasolineTiresVehicle Speed Control
I HAVE A 2005 FORD EXPEDITION LIMITED. MY COMPLAINT IS THE THROTTLE BODY FAILURE. WHEN DRIVING DOWN THE ROAD, THE ENGINE WILL SHUT DOWN AND YOU LOOSE ALL POWER TO THE VEHICLE. I HAVE HAD THIS HAPPEN AT SPEEDS OF 55+ MPH AS WELL AS SPEEDS OF APPROX LESS THAN 10 MPH, SUCH AS WHILE IN A PARKING LOT. THIS PROBLEM STARTED IN THE …
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I HAVE A 2005 FORD EXPEDITION LIMITED. MY COMPLAINT IS THE THROTTLE BODY FAILURE. WHEN DRIVING DOWN THE ROAD, THE ENGINE WILL SHUT DOWN AND YOU LOOSE ALL POWER TO THE VEHICLE. I HAVE HAD THIS HAPPEN AT SPEEDS OF 55+ MPH AS WELL AS SPEEDS OF APPROX LESS THAN 10 MPH, SUCH AS WHILE IN A PARKING LOT. THIS PROBLEM STARTED IN THE SUMMER OF 2009, AND HAS HAPPENED EVERY MONTH SINCE, SOMETIMES SEVERAL TIMES DURING THE MONTH. WE TOOK THE VEHICLE TO HAVE IT TESTED AND WERE TOLD IT WAS A TPS SENSOR. THAT HAS BEEN REPLACED ($75.00) BUT THE PROBLEM IS STILL HAPPENING. I HAVE DONE SOME RESEARCH ON THIS AND IT IS AN ONGOING PROBLEM WITH THE 2005 EXPEDITIONS. I PERSONALLY KNOW OF 2 OTHER PEOPLE THAT HAVE HAD THE SAME PROBLEM AND HAVE HAD TO HAVE THE ENTIRE THROTTLE BODY REPLACED, ONE OF WHICH HAS HAD IT REPLACED TWICE NOW. THIS IS A HUGE CONCERN SINCE YOU DO LOOSE ALL POWER AND HAVE TO TRY TO COAST TO THE SIDE OF THE ROAD, WHILE TRYING TO AVOID BEING HIT BY OTHER VEHICLES ON THE ROAD. MY CONCERN IS THAT WHEN THIS HAPPENS, THE RESULT WILL BE A ACCIDENT WHILE TRYING TO GET THE VEHICLE TO THE SIDE OF THE ROAD. THE REPAIR COST FOR JUST THE PARTS IS $600.00, BUT THIS DOES NOT INCLUDE THE LABOR. FORD NEEDS TO RECALL THIS PART BEFORE SOMEONE DOES DIE OR IS SERIOUSLY INJURED, AS IT IS A HUGE SAFETY CONCERN. FORD AND THEIR DEALERS ARE AWARE OF THE PROBLEM, YET THE ONLY RESOLUTION IS TO HAVE THE CONSUMER PAY FOR THE REPAIRS. I AM AFRAID TO DRIVE MY VEHICLE NOW BECAUSE OF THIS PROBLEM. I DO NOT HAVE THE OLD TPS SENSOR, BUT THE VEHICLE IS STILL DOING THIS AND DO STILL HAVE THE THROTTLE BODY THAT IS BAD ON THE VEHICLE FOR INSPECTION. WHEN THIS HAPPENS, THE INFORMATION CENTER IN THE DASH TELLS YOU TO "CHECK ELECTRONIC THROTTLE CABLE". *TR
NHTSA ODI #10316047
78,000 miles · Feb 24, 2010
Fuel System, GasolineVehicle Speed Control
2005 FORD EXPEDITION 78,000 MILES. IN THE LAST FEW MONTHS THE CAR AT TIMES HAS FELT AS THOUGH THERE IS LITTLE TO NO ACCELERATION, ALMOST LIKE THE CAR IS IN NEUTRAL. TODAY MY CAR STALLED AND I WAS ABLE TO DRIFT TO THE SIDE OF THE ROAD. THE "CHECK ELECTRONIC THROTTLE" LIGHT CAME ON. THE CAR IS AT THE DEALER NOW, WITH A $600+ R…
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2005 FORD EXPEDITION 78,000 MILES. IN THE LAST FEW MONTHS THE CAR AT TIMES HAS FELT AS THOUGH THERE IS LITTLE TO NO ACCELERATION, ALMOST LIKE THE CAR IS IN NEUTRAL. TODAY MY CAR STALLED AND I WAS ABLE TO DRIFT TO THE SIDE OF THE ROAD. THE "CHECK ELECTRONIC THROTTLE" LIGHT CAME ON. THE CAR IS AT THE DEALER NOW, WITH A $600+ REPAIR BILL. SEEMS THERE SHOULD BE A CHECK FOR SUCH SYSTEMS. WHAT WOULD HAVE HAPPENED HAD I BEEN ON A BUSIER STREET OR FREEWAY. *TR
NHTSA ODI #10313929
60,000 miles · Feb 24, 2010
Vehicle Speed Control
3RD INCIDENT OF THIS ISSUE WITH THIS VEHICLE AND MULTIPLE COMPLAINTS ONLINE. VEHICLE RUNS FINE AND THE WRENCH LIGHT WILL COME ON WITH A MESSAGE "ELECTRONIC THROTTLE CONTROL" THE VEHICLE REMAINS ON BUT THROTTLE DOES NOT OPERATE. ONE OF THE INCIDENTS HAPPENED IN AN INTERSECTION AND UNDER SIMILAR CIRCUMSTANCES WOULD HAVE RESULTED…
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3RD INCIDENT OF THIS ISSUE WITH THIS VEHICLE AND MULTIPLE COMPLAINTS ONLINE. VEHICLE RUNS FINE AND THE WRENCH LIGHT WILL COME ON WITH A MESSAGE "ELECTRONIC THROTTLE CONTROL" THE VEHICLE REMAINS ON BUT THROTTLE DOES NOT OPERATE. ONE OF THE INCIDENTS HAPPENED IN AN INTERSECTION AND UNDER SIMILAR CIRCUMSTANCES WOULD HAVE RESULTED IN A CRASH. IF THE VEHICLE IS TURNED OFF AND RESTARTED IT WORKS FINE UNTIL NEXT INCIDENT. THIS IS VERY DANGEROUS AND I AM VERY SURPRISED THAT THIS HAS NOT BEEN RECALLED WITH THE NUMEROUS COMPLAINTS OF THIS ISSUE DOCUMENTED ON THE INTERNET. *TR
NHTSA ODI #10313735
62,572 miles · Feb 12, 2010
Electronic Stability Control (esc)Vehicle Speed Control
2005 FORD EXPEDITION. WHILE DRIVING ON THE HWY THE "CHECK ELECTRONIC THROTTLE CONTROL" LIGHT CAME ON AND PUT THE VEHICLE IN "LIMP MODE" I HAD NO ACCELERATOR PEDAL CONTROL. DECEMBER 22, 2008. TAKEN TO DEALER, NO PROBLEM FOUND. CODE WAS " P2104". SAME THING HAPPENED AGAIN DECEMBER 20, 2009. TAKEN TO DEALER NO PROBLEM OR CODE FOUND…
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2005 FORD EXPEDITION. WHILE DRIVING ON THE HWY THE "CHECK ELECTRONIC THROTTLE CONTROL" LIGHT CAME ON AND PUT THE VEHICLE IN "LIMP MODE" I HAD NO ACCELERATOR PEDAL CONTROL. DECEMBER 22, 2008. TAKEN TO DEALER, NO PROBLEM FOUND. CODE WAS " P2104". SAME THING HAPPENED AGAIN DECEMBER 20, 2009. TAKEN TO DEALER NO PROBLEM OR CODE FOUND. WHEN THIS HAPPENS ,YOU HAVE NO POWER. YOU HAVE TO COAST TO THE SIDE OF THE ROAD AND CALL FOR HELP. *TR
NHTSA ODI #10308927
79,800 miles · Jan 20, 2010
Vehicle Speed Control
CAR WAS RUNNING FINE THEN BEEP AND WARNING SHOWS ON DASH SOMETHING ABOUT "ELECTRONIC THROTTLE CONTROL'. THE CAR IS STILL RUNNING BUT GAS PEDAL DOESN'T WORK. I WAS STUCK AT A STREET LIGHT STOPPED UNTIL I COULD TURN OFF AND RESTART THE CAR. THIS IS THE 2ND INCIDENT WITH THIS VEHICLE. IT HAPPENED THE FIRST TIME DRIVING OVER 50 MPH …
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CAR WAS RUNNING FINE THEN BEEP AND WARNING SHOWS ON DASH SOMETHING ABOUT "ELECTRONIC THROTTLE CONTROL'. THE CAR IS STILL RUNNING BUT GAS PEDAL DOESN'T WORK. I WAS STUCK AT A STREET LIGHT STOPPED UNTIL I COULD TURN OFF AND RESTART THE CAR. THIS IS THE 2ND INCIDENT WITH THIS VEHICLE. IT HAPPENED THE FIRST TIME DRIVING OVER 50 MPH ON A HIGHWAY AND HAD TO COAST TO THE SIDE OF THE ROAD. THERE IS APPARENTLY NOTHING THAT CAN BE FOUND WRONG AND NO WAY TO TELL IF IT IS GOING TO HAPPENED AGAIN AND WHY IT HAPPENED. I HAVE NOT DONE ANYTHING TO REPAIR SINCE I CAN NOT FIND A REASON AS TO WHY IT HAPPENED TO HAVE IT REPAIRED. *TR
NHTSA ODI #10300417
53,000 miles · Nov 16, 2009
Vehicle Speed Control
DRIVING 2005 FORD EXPEDITION PASSED THROUGH INTERSECTION DRIVING 45 MPH AND ALL OF A SUDDEN CAR LIGHT TURNED ON AND READ ELECTRONIC THROTTLE CONTROL FAILURE AND CAR IMMEDIATELY COULD NOT DRIVE OVER 5 MPH. I TURNED AND GOT OFF THE MAIN ROAD, SCARED THAT I WAS GOING TO GET HIT BY ANOTHER CAR. WAS ABLE TO TURN CAR BACK ON AFTER L…
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DRIVING 2005 FORD EXPEDITION PASSED THROUGH INTERSECTION DRIVING 45 MPH AND ALL OF A SUDDEN CAR LIGHT TURNED ON AND READ ELECTRONIC THROTTLE CONTROL FAILURE AND CAR IMMEDIATELY COULD NOT DRIVE OVER 5 MPH. I TURNED AND GOT OFF THE MAIN ROAD, SCARED THAT I WAS GOING TO GET HIT BY ANOTHER CAR. WAS ABLE TO TURN CAR BACK ON AFTER LEAVING THE CAR THEIR FOR A FEW HOURS, TOLD THAT I NEEDED TO REPLACE THE THROTTLE BODY AND I HAVE 53,000 AND NOT UNDER WARRENTLY. THIS IS A SAFETY CONCERN THIS COULD HAVE CAUSED A SERIOUS ACCIDENT! *TR
NHTSA ODI #10292431
45,000 miles · Oct 23, 2009
Vehicle Speed Control
TL* THE CONTACT OWNS A 2005 FORD EXPEDITION. WHILE DRIVING 25 MPH THE CHECK ELECTRONIC THROTTLE CONTROL WARNING LIGHT ILLUMINATED ON THE INSTRUMENT CONTROL PANEL, AND THEN THE VEHICLE STALLED. HE WAS ABLE TO SAFELY RESTART THE VEHICLE TO RESUME NORMAL VEHICLE OPERATION. THE DEALER WAS NOTIFIED, AND A TECHNICIAN STATED THAT THE…
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TL* THE CONTACT OWNS A 2005 FORD EXPEDITION. WHILE DRIVING 25 MPH THE CHECK ELECTRONIC THROTTLE CONTROL WARNING LIGHT ILLUMINATED ON THE INSTRUMENT CONTROL PANEL, AND THEN THE VEHICLE STALLED. HE WAS ABLE TO SAFELY RESTART THE VEHICLE TO RESUME NORMAL VEHICLE OPERATION. THE DEALER WAS NOTIFIED, AND A TECHNICIAN STATED THAT THEY WERE AWARE OF THE FAILURE, BUT BECAUSE THEY WERE NO RECALLS THEY WOULD NOT PROVIDE ANY ASSISTANCE. THE VEHICLE WILL BE REPAIRED. THE FAILURE AND CURRENT MILEAGES WERE 45000.
NHTSA ODI #10289630
120,000 miles · Aug 18, 2009
Vehicle Speed Control
OWN A 2005 FORD EXPEDITION, IN THE PAST 6 MONTHS AT ABOUT A RATE OF ONCE/MONTH THE ENGINE WILL SHUT OFF LOSS OF POWER WITH DIFFICULTY STEERING, THE VEHICLE HAS INDICATED THAT THE ELECTRONIC THROTTLE CONTROL IS THE ISSUE. ONCE I'M ABLE TO COAST THE VEHICLE TO THE SIDE OF THE ROAD I SHUT OFF THE VEHICLE AND RESTART WITHIN A FEW M…
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OWN A 2005 FORD EXPEDITION, IN THE PAST 6 MONTHS AT ABOUT A RATE OF ONCE/MONTH THE ENGINE WILL SHUT OFF LOSS OF POWER WITH DIFFICULTY STEERING, THE VEHICLE HAS INDICATED THAT THE ELECTRONIC THROTTLE CONTROL IS THE ISSUE. ONCE I'M ABLE TO COAST THE VEHICLE TO THE SIDE OF THE ROAD I SHUT OFF THE VEHICLE AND RESTART WITHIN A FEW MINUTES AND ABLE TO CONTINUE UNTIL THE NEXT INCIDENT WITH THIS PROBLEM. I HAVE RESEARCHED THROUGH THE INTERNET AND HAVE FOUND NUMEROUS COMPLAINTS IN REFERENCE TO THIS SAME ISSUE WITH SOME INVOLVING ACCIDENTS DUE TO THE INADVERTENT LOSS OF POWER. I HAVE CONTACTED THE FORD MOTOR COMPANY AND THEY WILL ONLY TELL ME THAT THEY WILL NOT DO ANYTHING TO COVER THIS. THIS IS A SERIOUS SAFETY ISSUE AND NEEDS TO BE ADDRESSED BEFORE SOMEONE IS KILLED IN A MOTOR VEHICLE ACCIDENT DUE TO THIS PROBLEM. *TR
NHTSA ODI #10280894
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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