IllustrationTHE ENGINE JUST STALLED AND THE MESSAGE "ENGINE FAIL SAFE MODE" APPEARED. LUCKILY WE WERE RIGHT AT A PARKING LOT THAT WE ROLLED INTO WITH MY HUSBAND STEERING. WE HAD JUST PULLED OFF THE INTERSTATE TRAVELING 65 MPH. IT COULD HAVE RESULTED IN INJURIES AND/OR DEATH. FORD SHOULD FIX THIS PROBLEM. *TR
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 →How this year compares
Owner complaints by model year
Compare all Expedition years →Counts vary with age, sales and reporting. They are not failure rates.
What owners reported most
All reported categories
Tap a category to read its complaints. One report may name several components.
When problems were reported
Mileage at the reported incident
250–25K
4025–50K
7950–75K
6275–100K
60100–150K
23150K+
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
What owners actually said
315 reportsWHILE DRIVING AT 40 MPH ENGINE STOPPED WORKING MAKING BRAKES AND STEERING FAIL. LIMPED OFF BUSY ROAD LUCKILY! ENGINE LIGHT SHOWED ELECTRONIC THROTTLE FAILURE. NOW CHECK ENGINE LIGHT IS ON. GOING TO DEALERS FOR REPAIR TODAY-SINCE THIS IS AN OBVIOUS PROBLEM FOR FORD WHY HAVEN'T THEY ADDRESSED IT! COULD BE DEADLY IF FAILS IN HEA…
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WHILE DRIVING AT 40 MPH ENGINE STOPPED WORKING MAKING BRAKES AND STEERING FAIL. LIMPED OFF BUSY ROAD LUCKILY! ENGINE LIGHT SHOWED ELECTRONIC THROTTLE FAILURE. NOW CHECK ENGINE LIGHT IS ON. GOING TO DEALERS FOR REPAIR TODAY-SINCE THIS IS AN OBVIOUS PROBLEM FOR FORD WHY HAVEN'T THEY ADDRESSED IT! COULD BE DEADLY IF FAILS IN HEAVY TRAFFIC CONDITIONS. *TR
ENGINE SHUTS OFF WHILE DRIVING. *TR
WHILE I WAS DRIVING DONE THE INTERSTATE, MY FORD EXPEDITION LOST ALL POWER AND COMPLETELY STALLED. LUCKILY, I WAS ABLE TO GET IT OFF THE ROAD TO THE SHOULDER WITHOUT ANY INCIDENT. THIS IS THE THIRD TIME IT HAS HAPPENED TO ME. PREVIOUSLY, I HAD MY FUEL PUMP SENSOR CHANGED BECAUSE MY CHECK ENGINE LIGHT CAME ON AND THAT IS WHAT IT …
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WHILE I WAS DRIVING DONE THE INTERSTATE, MY FORD EXPEDITION LOST ALL POWER AND COMPLETELY STALLED. LUCKILY, I WAS ABLE TO GET IT OFF THE ROAD TO THE SHOULDER WITHOUT ANY INCIDENT. THIS IS THE THIRD TIME IT HAS HAPPENED TO ME. PREVIOUSLY, I HAD MY FUEL PUMP SENSOR CHANGED BECAUSE MY CHECK ENGINE LIGHT CAME ON AND THAT IS WHAT IT INDICATED; HOWEVER, THE PROBLEM STILL EXITS AND MY MECHANICS ARE BAFFLED. VERY DANGEROUS! *TR
ENGINE FAILSAFE MODE CAME ON IN THE MIDDLE OF DRIVING AND THE TRUCK JUST SHUT OFF IN THE MIDDLE OF THE ROAD. I HAD TO TURN IT OFF AND RESTART IT...IT HAPPENED THREE TIMES IN ONE TRIP. *TR
DRIVING IN CITY TRAFFIC, AT APPROXIMATELY 35 MPH. THE ELECTRONIC THROTTLE CONTROL LIGHT CAME ON AND ENGINE DIED. WE WERE ABLE TO COAST TO GAS STATION. THE VEHICLE STARTED RIGHT UP AND EVERYTHINGS WORKED FINE. THE NEXT DAY TOOK VEHICLE TO FORD DEALERSHIP. AFTER TROUBLESHOOTING, THEY WERE NOT REALLY SURE OF WHAT WAS THE PROBLE…
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DRIVING IN CITY TRAFFIC, AT APPROXIMATELY 35 MPH. THE ELECTRONIC THROTTLE CONTROL LIGHT CAME ON AND ENGINE DIED. WE WERE ABLE TO COAST TO GAS STATION. THE VEHICLE STARTED RIGHT UP AND EVERYTHINGS WORKED FINE. THE NEXT DAY TOOK VEHICLE TO FORD DEALERSHIP. AFTER TROUBLESHOOTING, THEY WERE NOT REALLY SURE OF WHAT WAS THE PROBLEM. BUT THEY SUGGESTED CHANGING THE THROTTLE BODY. WE DECIDED TO TAKE VEHICLE HOME. VEHICLE WORKED FINE UNTIL YESTERDAY, THE PROBLEM OCCURRED AGAIN. THIS IS AN UNSAFE CONDITION. THERE IS A LARGE ABOUT OF E-MAIL TRAFFIC ABOUT THIS SAME PROBLEM, AND FORD HAS NOT ISSUED A RECALL. *TR
THE SPARK PLUG BROKE IN THE ENGINE COSTING A LOT OF MONEY TO REPAIR. NOW ANOTHER ONE IS STUCK AND I CANT AFFORD TO GET IT FIXED. THIS COULD POSSIBLY CAUSE FIRE AND CREATE A SAFETY HAZARD. THERE ARE NUMEROUS COMPLAINTS OUT THERE AND THIS REALLY NEEDS TO BE A RECALL SITUATION. *TR
WAS DRIVING AROUND 40 MILES PER HR AND ENGINE JUST QUIT. NO POWER STEERING. WARNING LIGHT CAME ON REGARDING THROTTLE. LUCKILY WE WERE NOT ON THE INTERSTATE AND COULD PULL OVER. MY SON WILL BE TURNING 16 IN A FEW MONTHS AND HE WAS GOING TO BE DRIVING THIS. NOW WE ARE WORRIED. THERE ARE SO MANY COMPLAINTS ON LINE. FORD NEED…
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WAS DRIVING AROUND 40 MILES PER HR AND ENGINE JUST QUIT. NO POWER STEERING. WARNING LIGHT CAME ON REGARDING THROTTLE. LUCKILY WE WERE NOT ON THE INTERSTATE AND COULD PULL OVER. MY SON WILL BE TURNING 16 IN A FEW MONTHS AND HE WAS GOING TO BE DRIVING THIS. NOW WE ARE WORRIED. THERE ARE SO MANY COMPLAINTS ON LINE. FORD NEEDS TO RECALL THIS. SOMEONE WILL END UP BEING HURT OVER THIS. I HAVE SEEN THAT REPLACING THROTTLE DOES NOT FIX IT. WE TURNED CAR OFF AND RESTARTED IT AND IT WORKED FINE. YOU DO NOT KNOW WHEN THIS WILL HAPPEN. *TR
WHILE TRAVELING DOWN THE FREEWAY AT 70 MPH, THE VEHICLE DIED. IT WOULD NOT RESTART. AFTER 1 HOUR VEHICLE THE VEHICLE STARTED AND THEN DIED WITHIN SECONDS. THE FUEL FILTER AND FUEL PUMP WERE REPLACED BECAUSE ALL INDICATIONS LEAD TO BELIEVE THAT THE FUEL PUMP WAS BAD. AFTER REPLACEMENT OF THE FUEL PUMP, VEHICLE WOULD NOT START. LO…
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WHILE TRAVELING DOWN THE FREEWAY AT 70 MPH, THE VEHICLE DIED. IT WOULD NOT RESTART. AFTER 1 HOUR VEHICLE THE VEHICLE STARTED AND THEN DIED WITHIN SECONDS. THE FUEL FILTER AND FUEL PUMP WERE REPLACED BECAUSE ALL INDICATIONS LEAD TO BELIEVE THAT THE FUEL PUMP WAS BAD. AFTER REPLACEMENT OF THE FUEL PUMP, VEHICLE WOULD NOT START. LOOKING ON THE INTERNET FOR POSSIBLE SOLUTIONS FROM OTHERS, I FOUND ONE PERSON WITH THE SAME PROBLEM AND FOLLOWED THEIR ADVISE ON HOW TO FIX IT. I FOUND THE "DRIVERS MODULE" ON THE BACK TOPSIDE OF THE FRAME. WHEN THE MODULE WAS REMOVED, IT WAS FOUND TO HAVE TWO LARGE SECTIONS OF CORROSION ABOUT 1/4 INCH THICK. WHEN THE CHUNKS WERE KNOCKED OFF, UNDER THEM WERE TWO HOLES THROUGH THE SIDE OF THE MODULE AND THE CIRCUIT WAS BURNT, THE PLUG WAS ALSO STARTING TO CORRODE. THE PLACEMENT FOR THE MODULE IS A TERRIBLE SPOT. IT IS ALUMINUM ATTACHED TO A STEEL FRAME, WITH NOTHING SEPARATING THEM. WHEN THE NEW MODULE ARRIVED, IT NOW HAS A RUBBER GASKET TO KEEP THEM SEPARATE. THIS LOOKS LIKE A DESIGN FLAW ON FORD'S PART AND A RECALL SHOULD BE ORDERED. FORD SHOULD FURTHER REFUND THE COST OF THE FUEL PUMP BECAUSE ALL INDICATIONS SHOW THAT THE FUEL PUMP IS BAD, WHEN IN TRUTH IT IS THE MODULE AND NOT THE FUEL PUMP. *TR
FIRST TIME IT OCCURRED I WAS TRAVELING TO WORK THE CAR STALLED WHILE DRIVING APPROX. 20 MPH AND THERE WAS NO CONTROL OF THE CAR - WAS ABLE TO MOVE TO SIDE OF ROAD AND RESTART. FAULT ON THE CONSOLE WAS "ELECTRONIC THROTTLE". HAS HAPPEN APPROX 4 MORE TIMES AT VARIOUS SPEEDS AND CONDITIONS WITH THREE DIFFERENT DRIVERS. NO PROBLE…
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FIRST TIME IT OCCURRED I WAS TRAVELING TO WORK THE CAR STALLED WHILE DRIVING APPROX. 20 MPH AND THERE WAS NO CONTROL OF THE CAR - WAS ABLE TO MOVE TO SIDE OF ROAD AND RESTART. FAULT ON THE CONSOLE WAS "ELECTRONIC THROTTLE". HAS HAPPEN APPROX 4 MORE TIMES AT VARIOUS SPEEDS AND CONDITIONS WITH THREE DIFFERENT DRIVERS. NO PROBLEM EVER FOUND BY DEALER. HAS HAPPENED AT HIGH SPEED ON THE FREEWAY COMPLETE LOSS OF STEERING AND POWER OCCURS MORE CONCERNING IT CAN HAPPEN AT ANY TIME WITHOUT WARNING. I FIND THIS TO BE EXTREMELY DANGEROUS AND A DEATH TRAP WAITING TO HAPPEN. THE LAST TIME IT OCCURRED WHEN BY TEENAGE DAUGHTER WAS DRIVING SHE WAS SCARED TO DEATH REFUSING TO DRIVE IT HOME. THIS REMINDED ME OF TOYOTA PRIUS SO I TOOK IT UPON MYSELF TO REPORT MY INCIDENTS. LOOKING AT THE INTERNET I NOW FIND IT OCCURS FREQUENTLY AND IT IS NOT AN ISOLATED CASE. *TR
Official recalls
0No 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
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