NHTSA owner reports · September 18, 2026 snapshot.
Vehicle Speed Control complaints
66 reportsClear category filter52,000 miles · Apr 6, 2009
Electrical SystemVehicle Speed Control
I WAS DRIVING 55MPH ON HIGHWAY, WHEN ALL OF A SUDDEN THERE WAS NO POWER TO GAS PEDAL. THE CHECK ELECTRONIC THROTTLE CONTROL LIGHT FLASHED, I PULLED OVER THREE LANES TO SIDE OF ROAD. I SAT THERE TRYING TO START VEHICLE CONTINUOUSLY, FINALLY AFTER 10 MINUTES IT STARTED. MY 9 MONTH OLD DAUGHTER AND I WAS ALMOST KILLED ON THE HIGHWA…
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I WAS DRIVING 55MPH ON HIGHWAY, WHEN ALL OF A SUDDEN THERE WAS NO POWER TO GAS PEDAL. THE CHECK ELECTRONIC THROTTLE CONTROL LIGHT FLASHED, I PULLED OVER THREE LANES TO SIDE OF ROAD. I SAT THERE TRYING TO START VEHICLE CONTINUOUSLY, FINALLY AFTER 10 MINUTES IT STARTED. MY 9 MONTH OLD DAUGHTER AND I WAS ALMOST KILLED ON THE HIGHWAY DUE TO THIS PROBLEM. MY VEHICLE IS NOW RUNNING TERRIBLE. I CAME HOME TO SEE IF I COULD FIND ANYTHING ON THE INTERNET AND FOUND THAT THIS IS COMMON IN THE 2005 FORD EXPEDITION AND NOTHING IS BEING DONE. IS IT GOING TO TAKE SOMEONE GETTING KILLED FOR FORD TO RECALL THIS PROBLEM? IT OBVIOUSLY IS A MANUFACTURING PROBLEM AND THEY ARE DOING NOTHING ABOUT IT. I WILL BE CONTACTING FORD TOMORROW TO SEE ABOUT GETTING MY VEHICLE IN AND FIXING THIS. *TR
NHTSA ODI #10264202
60,135 miles · Mar 10, 2009
Vehicle Speed Control
2005 FORD EXPEDITION - LOSES COMPLETE POWER UNEXPECTEDLY. HAPPENS OFF-AND-ON. DIFFICULT TO RE-CREATE PROBLEM TO MECHANIC. BLOGS FULL OF SIMILAR EXPERIENCES. VERY UNSAFE CONDITION WHILE ON AN EXPRESSWAY. RECEIVE ERROR MESSAGE - "CHECK THROTTLE CONTROL". COST $500 TO REPLACE THROTTLE BODY. SEEMS TO BE POPULAR PROBLEM IN THE 2005 E…
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2005 FORD EXPEDITION - LOSES COMPLETE POWER UNEXPECTEDLY. HAPPENS OFF-AND-ON. DIFFICULT TO RE-CREATE PROBLEM TO MECHANIC. BLOGS FULL OF SIMILAR EXPERIENCES. VERY UNSAFE CONDITION WHILE ON AN EXPRESSWAY. RECEIVE ERROR MESSAGE - "CHECK THROTTLE CONTROL". COST $500 TO REPLACE THROTTLE BODY. SEEMS TO BE POPULAR PROBLEM IN THE 2005 EXPEDITION. *TR
NHTSA ODI #10261405
28,800 miles · Jan 3, 2009
Vehicle Speed ControlCrash
WHEN I TURNED THE ENGINE ON AND PUT CAR ON REVERSE IT SPEED OUT OF CONTROL, IMMEDIATELY TRY TO PUSH ON BRAKES BUT IT DIDN'T STOP AND I CRASHED INTO A PALM TREE. *TR
NHTSA ODI #10253679
63,130 miles · Dec 23, 2008
Power TrainVehicle Speed Control
"CHECK ELECTRONIC THROTTLE" MESSAGE APPEARED AND ACCELERATOR PEDAL BECAME INOPERATIVE. THIS IS THE SECOND TIME THIS HAS OCCURRED. SHIFTED VEHICLE INTO NEUTRAL, RESTARTED ENGINE WHILE ROLLING ALONG AND ERROR WAS CORRECTED. *TR
NHTSA ODI #10252614
63,000 miles · Dec 23, 2008
Power TrainVehicle Speed Control
"CHECK ELECTRONIC THROTTLE" MESSAGE APPEARED AND ACCELERATOR PEDAL BECAME UNRESPONSIVE IN TRAFFIC. PULLED OVER, RESTARTED ENGINE AND ISSUE CORRECTED ITSELF. *TR
NHTSA ODI #10252613
49,511 miles · Dec 11, 2007
Electrical SystemFuel System, GasolineVehicle Speed Control
I HAVE A 2005 FORD EXPEDITION, EDDIE BAUER. MOST RECENTLY (2 WEEKS AGO), MY CHECK ELECTRONIC THROTTLE LIGHT CAME ON, I CALLED MY LOCAL DEALER AND PLANNED TO TAKE IT IN THE NEXT DAY. I WORK CLOSE TO HOME AND HAVE LIMITED DRIVING DISTANCE. ON THE WAY HOME, THE THROTTLE WENT COMPLETELY OUT AND THE VEHICLE CUT OFF ON THE SIDE OF …
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I HAVE A 2005 FORD EXPEDITION, EDDIE BAUER. MOST RECENTLY (2 WEEKS AGO), MY CHECK ELECTRONIC THROTTLE LIGHT CAME ON, I CALLED MY LOCAL DEALER AND PLANNED TO TAKE IT IN THE NEXT DAY. I WORK CLOSE TO HOME AND HAVE LIMITED DRIVING DISTANCE. ON THE WAY HOME, THE THROTTLE WENT COMPLETELY OUT AND THE VEHICLE CUT OFF ON THE SIDE OF THE ROAD AND WAS UNABLE TO BE RESTARTED AND HAD TO BE TOWED. MY LOCAL DEALER DID FIX IT IN A TIMELY MANNER. HOWEVER...THIS IS NOT THE FIRST PROBLEM. WE BOUGHT IT BRAND NEW AND WITHIN A MONTH THE FUEL INJECTOR WENT OUT WHEN I WAS COMING BACK HOME FROM OUT OF TOWN, MY DRIVERS SIDE SEAT ADJUSTMENT WENT OUT TWICE AND HAD TO BE REPLACED. I AM SHORT AND HAD TO DRIVE WITH MY SEAT ALL THE WAY BACK. 2 CAM PHASERS HAD TO BE REPLACED BACK IN THE SUMMER AND THEN MOST RECENTLY THIS. I HAVE 2 SMALL CHILDREN AND WOULD PREFER A DEPENDABLE VEHICLE. I FILED A FORMAL COMPLAINT WITH FORD AND HEARD FROM THEM TODAY OF WHICH I WAS TOLD THAT HAVING 49,000 MILES ON MY VEHICLE IT WAS NOT UNUSUAL FOR PARTS TO GO BAD. I LIVE ON A HARD SURFACE ROAD AND DRIVE TO WORK, NORMAL DAY TO DAY ACTIVITIES AND OF COURSE VACATION. THE ONLY THING THEY WOULD DO WAS UPGRADE MY WARRANTY TO COVER THE TRANSMISSION. IT ALREADY HAS THE EXTENDED WARRANTY. I AM DISAPPOINTED THEY WOULD NOT STAND BY THEIR PRODUCT. I HAVE OWNED 2 TOYOYTA'S IN THE PAST AND PLAN TO GO BACK TO A TOYOTA AND A FORD COULD NOT BE GIVEN TO ME AGAIN. *TR
NHTSA ODI #10211478
70,298 miles · Nov 17, 2007
Vehicle Speed Control
I WAS TRAVELING AT 60 MPH AND SUDDENLY I HEARD AN ALARM AND THE DASH INDICATED "CHECK ELECTRONIC THROTTLE CONTROL. AT THAT INSTANT THE VEHICLE STALLED. I WAS ABLE TO MANEUVER TO THE BURM. TRIED TO START BUT WOULD NOT RESPOND. FINALLY AFTER ABOUT TWO MINUTES I WAS ABLE TO START THE VEHICLE AND RETURN TO WORK. TOOK VEHICLE TO BASS…
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I WAS TRAVELING AT 60 MPH AND SUDDENLY I HEARD AN ALARM AND THE DASH INDICATED "CHECK ELECTRONIC THROTTLE CONTROL. AT THAT INSTANT THE VEHICLE STALLED. I WAS ABLE TO MANEUVER TO THE BURM. TRIED TO START BUT WOULD NOT RESPOND. FINALLY AFTER ABOUT TWO MINUTES I WAS ABLE TO START THE VEHICLE AND RETURN TO WORK. TOOK VEHICLE TO BASS FORD SHERFFIELD VILLAGE OHIO. THEY ARE INVESTIGATING. *TR
NHTSA ODI #10209236
1,000 miles · Apr 17, 2007
Service Brakes, HydraulicVehicle Speed Control
BRAKE PEDAL AND GAS PEDALS TOO CLOSE. MANY TIMES GAS PEDAL HAS BEEN DEPRESSED WHILE TRYING TO ONLY DEPRESS THE BRAKE PEDAL.*AK
NHTSA ODI #10188098
Mileage unknown · Jan 2, 2007
Fuel System, GasolineVehicle Speed Control
I OWN A 2005 FORD EXPEDITION (LIMITED) ON A NUMBER OF OCCASIONS MY VEHICLES MOTOR HAS REVIVED UP AND I HAD TO PUT MY FOOT ON THE BRAKE VERY HARD TO PREVENT CRASHING INTO VEHICLES IN FRONT OF ME... IT ALSO HAPPENED ONE TIME WHEN I WAS GOING ABOUT 50 MPH AND THE CAR FOR NOW APPARENT REASON ACCELERATED TO 60 VERY QUICKLY. I HAV…
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I OWN A 2005 FORD EXPEDITION (LIMITED) ON A NUMBER OF OCCASIONS MY VEHICLES MOTOR HAS REVIVED UP AND I HAD TO PUT MY FOOT ON THE BRAKE VERY HARD TO PREVENT CRASHING INTO VEHICLES IN FRONT OF ME... IT ALSO HAPPENED ONE TIME WHEN I WAS GOING ABOUT 50 MPH AND THE CAR FOR NOW APPARENT REASON ACCELERATED TO 60 VERY QUICKLY. I HAVE REPORTED THIS TO THE DEALER ON THREE SEPARATE OCCASIONS AND THEY ADVISE THAT THERE IS NOTHING WRONG WITH THE VEHICLE. (MARONEY FORD, DELRAY BEACH, FL) *JB
NHTSA ODI #10177559
12,433 miles · Oct 25, 2006
Vehicle Speed Control
DT*: THE CONTACT STATED WHILE AT A STOP LIGHT, THE CONTACT DEPRESSED THE BRAKE PEDAL AND THE VEHICLE BEGAN TO ACCELERATE AS IF CRUISE CONTROL WAS ENGAGED. THE CONTACT TRIED TO DEPRESS THE BRAKE PEDAL HARDER UNTIL IT GOES AWAY. THERE WAS NO WARNING SIGNAL PRIOR TO THE INCIDENT. THE PROBLEMS PERSISTED INTERMITTENTLY WHILE THE VE…
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DT*: THE CONTACT STATED WHILE AT A STOP LIGHT, THE CONTACT DEPRESSED THE BRAKE PEDAL AND THE VEHICLE BEGAN TO ACCELERATE AS IF CRUISE CONTROL WAS ENGAGED. THE CONTACT TRIED TO DEPRESS THE BRAKE PEDAL HARDER UNTIL IT GOES AWAY. THERE WAS NO WARNING SIGNAL PRIOR TO THE INCIDENT. THE PROBLEMS PERSISTED INTERMITTENTLY WHILE THE VEHICLE WAS IDLING. THE VEHICLE WAS TAKEN TO THE SERVICE DEALER WHO COULD NOT DUPLICATE THE PROBLEM. THE SECOND TIME, THE SERVICE DEALER ADJUSTED THE CALIBRATION FOR A TEMPORARY REMEDY. AFTER A COUPLE OF MONTHS, THE PROBLEM PERSISTED AND THE VEHICLE WAS TAKEN BACK TO THE DEALER, WHO INSTALLED A FLIGHT RECORD BOX. THE CONTACT KEPT THE FLIGHT RECORD BOX FOR TWO WEEKS AND RETURNED TO THE SERVICE DEALER BUT THE READINGS COULD NOT BE DETERMINED. THE VEHICLE WAS TAKEN TO THE DEALER SIX SEPARATE TIMES FOR THE SAME PROBLEM. THE MANUFACTURER WAS NOTIFIED AND DID NOT OFFERED ANY RESOLUTION.
NHTSA ODI #10171818
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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