NHTSA owner reports · September 18, 2026 snapshot.
What owners actually said
315 reports92,000 miles · Jan 22, 2011
Electrical System
I WAS TRAVELING W/B ON I-96 NEAR THE OKEMOS EXIT WHEN MY 2005 FORD EXPEDITION'S ENGINE SUDDENLY SHUT OFF. A WARNING STATING, "CHECK ELECTRONIC THROTTLE CONTROL" CAME ON. I EXITED THE EXPRESS WAY. THE ENGINE STILL RAN IN IDLE, BUT WOULD NOT RUN ANY FASTER THAN THAT. I PULLED INTO A PARKING LOT AND SHUT OFF THE ENGINE. I RESTARTED…
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I WAS TRAVELING W/B ON I-96 NEAR THE OKEMOS EXIT WHEN MY 2005 FORD EXPEDITION'S ENGINE SUDDENLY SHUT OFF. A WARNING STATING, "CHECK ELECTRONIC THROTTLE CONTROL" CAME ON. I EXITED THE EXPRESS WAY. THE ENGINE STILL RAN IN IDLE, BUT WOULD NOT RUN ANY FASTER THAN THAT. I PULLED INTO A PARKING LOT AND SHUT OFF THE ENGINE. I RESTARTED THE VEHICLE AND IT BEGAN RUNNING NORMALLY AGAIN. APPROXIMATELY FIVE MINUTES LATER, WHILE I WAS EXITING A PARKING LOT, THE SAME THING HAPPENED AGAIN. THIS TIME THE ENGINE WOULD NOT RUN AT ALL AND THE POWER STEERING STOPPED WORKING. I RESTARTED THE VEHICLE AGAIN AND IT RAN FINE. HOWEVER, THE CHECK ENGINE LIGHT IS NOW ILLUMINATED. I HAVE RESEARCHED ONLINE AND HAVE OBSERVED THAT THIS IS A PROBLEM FOR MANY PEOPLE. THERE ARE FORUMS OF COMPLAINTS ABOUT THIS EXACT SAME PROBLEM FOUND ON COUNTLESS WEBSITES. FURTHERMORE, THIS IS A VERY DANGEROUS PROBLEM. IF I WOULD HAVE BEEN TRAVELING THROUGH AN INTERSECTION WHEN THIS OCCURRED I COULD HAVE BEEN HIT. THIS EXPEDITION HAS HAD MANY ELECTRICAL PROBLEMS INCLUDING: TURN SIGNAL FAILURE, FUEL PUMP MODULE FAILURE, LIGHTS AND SIGNALS RANDOMLY NOT WORKING, WIPERS RANDOMLY NOT WORKING, ETC. I HAVE SPENT A LOT OF MONEY REPAIRING THESE ISSUES. I AM FED UP WITH THEM AND I AM CONTACTING YOU TODAY BECAUSE THE ELECTRICAL ISSUES IN THIS CAR ARE FINALLY BECOMING UNSAFE. I HAVE ALSO CONTACTED FORD AND AM WAITING FOR A RESPONSE. MY VEHICLE ONLY HAS APPROXIMATELY 92,000 MILES ON IT AND IS STILL UNDER AN EXTENDED POWERTRAIN WARRANTY. *TR
NHTSA ODI #10378250
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
60,000 miles · Jan 18, 2011
Electrical SystemEngine And Engine CoolingSteering
WHILE TRAVELING 50 MPH ON BUSY STREET CAR POWER FAILED, SHUTTING OFF COMPLETELY INCLUDING LOSS OF POWER STEERING. ENGINE FAILURE LIGHT CAME ON. RESTARTED AFTER THAT AND DROVE FINE. SINCE THEN IT HAS OCCURRED 3 TIMES OVER LAST MONTH. LAST WEEK OCCURRED AT WHEN I WAS ATTEMPTING TO TURN WITH A TURN SIGNAL BUT SHUT OFF BEFORE I …
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WHILE TRAVELING 50 MPH ON BUSY STREET CAR POWER FAILED, SHUTTING OFF COMPLETELY INCLUDING LOSS OF POWER STEERING. ENGINE FAILURE LIGHT CAME ON. RESTARTED AFTER THAT AND DROVE FINE. SINCE THEN IT HAS OCCURRED 3 TIMES OVER LAST MONTH. LAST WEEK OCCURRED AT WHEN I WAS ATTEMPTING TO TURN WITH A TURN SIGNAL BUT SHUT OFF BEFORE I COULD MAKE THE TURN. THIS IS A LIFE THREATENING PROBLEM AND NEEDS TO BE RECALLED. THOUGHT IT HAD TO DO WITH LOW GAS TANK BUT HAD PLENTY OF GAS LAST WEEK. *TR
NHTSA ODI #10377708
113,000 miles · Jan 13, 2011
Engine And Engine Cooling
DRIVING ON FREEWAY IN MY 2005 FORD EXPEDITION, WHEN I LOST POWER AND BRAKES AND THE CHECK ENGINE LIGHT CAME ON. COASTED TO THE SIDE OF FREEWAY. VERY DANGEROUS INCIDENT. *TR
NHTSA ODI #10376547
85,000 miles · Jan 11, 2011
Vehicle Speed Control
TL*THE CONTACT OWNS A 2005 FORD EXPEDITION. WHILE DRIVING APPROXIMATELY 40 MPH THE VEHICLE MADE A BEEPING NOISE AND A WARNING LIGHT WAS DISPLAYED ON THE DASHBOARD INDICATING TO CHECK THE ELECTRONIC THROTTLE CONTROL. HE LOST ALL CONTROL OF THE VEHICLE WHEN THE ACCELERATOR PEDAL WAS ENGAGED. HE COASTED THE VEHICLE ONTO THE SIDE OF…
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TL*THE CONTACT OWNS A 2005 FORD EXPEDITION. WHILE DRIVING APPROXIMATELY 40 MPH THE VEHICLE MADE A BEEPING NOISE AND A WARNING LIGHT WAS DISPLAYED ON THE DASHBOARD INDICATING TO CHECK THE ELECTRONIC THROTTLE CONTROL. HE LOST ALL CONTROL OF THE VEHICLE WHEN THE ACCELERATOR PEDAL WAS ENGAGED. HE COASTED THE VEHICLE ONTO THE SIDE OF THE ROAD, TURNED THE VEHICLE OFF AND BACK ON. THE VEHICLE BEGAN TO FUNCTION NORMALLY. HE CALLED AN AUTHORIZED DEALER WHO ORDERED THE PARTS BASED ON HIS DESCRIPTION OF THE FAILURE. THE VEHICLE HAD NOT BEEN REPAIRED WHEN THE COMPLAINT WAS FILED. THE FAILURE AND CURRENT MILEAGES WERE 85,000.
NHTSA ODI #10376271
69,400 miles · Jan 4, 2011
Electrical SystemFuel System, GasolineVehicle Speed Control
THIS IS THE FOURTH 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 …
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THIS IS THE FOURTH 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 #4), THE CAR WAS TRAVELING AT APPROXIMATELY 10 MPH AND WAS TURNING RIGHT INTO A SUPERMARKET PARKING LOT IN CHEVY CHASE, MARYLAND. AS THE CAR PULLED INTO THE PARKING LOT, THE CAR LOST THE ABILITY TO ACCELERATE, THE "CHECK ELECTRONIC THROTTLE CONTROL" WARNING APPEARED IN THE DASHBOARD MESSAGE CENTER. THANKFULLY, THE CAR HAD ENOUGH MOMENTUM TO SAFELY PULL INTO A PARKING SPACE WITHOUT FURTHER INCIDENT. THE DRIVER TURNED OFF THE IGNITION, WAITED APPROXIMATELY 5 MINUTES, AND THEN STARTED THE CAR. THE DASHBOARD WARNING LIGHT WAS NO LONGER ILLUMINATED, AND THE CAR WAS ABLE TO ACCELERATE NORMALLY. *TR
NHTSA ODI #10374084
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
36,000 miles · Dec 19, 2010
Engine And Engine CoolingSteeringVehicle Speed Control
WHILE DRIVING ON US 95 NORTH THE VEHICLE ALL OF THE SUDDEN STALLED. THIS HAS HAPPENED TWICE BEFORE WHILE DRIVING AT SPEEDS OF 60 AND GREATER ON BUSY INTERSTATES. THE ENGINE JUST STOPS AND THE CAR MUST COAST TO THE SIDE OF THE ROAD AND SIT FOR A FEW MINUTES AND THEN IT WILL START AGAIN AND RUN FINE FOR AT LEAST A WEEK OR TWO. …
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WHILE DRIVING ON US 95 NORTH THE VEHICLE ALL OF THE SUDDEN STALLED. THIS HAS HAPPENED TWICE BEFORE WHILE DRIVING AT SPEEDS OF 60 AND GREATER ON BUSY INTERSTATES. THE ENGINE JUST STOPS AND THE CAR MUST COAST TO THE SIDE OF THE ROAD AND SIT FOR A FEW MINUTES AND THEN IT WILL START AGAIN AND RUN FINE FOR AT LEAST A WEEK OR TWO. RECENTLY THIS HAS BEEN HAPPENING EVERY COUPLE OF MONTHS. THE FIRST INCIDENT WAS IN JAN OF 2010 ON A TRIP FROM MISSOURI TO VIRGINIA. NOW THAT WE LIVE IN VIRGINIA, NEAR DC THIS IS SOMETHING THAT WE FIND VERY DANGEROUS ESPECIALLY WITH FOUR CHILDREN IN THE CAR.
NHTSA ODI #10371673
58,000 miles · Dec 16, 2010
Vehicle Speed Control
TL*THE CONTACT OWNS A 2005 FORD EXPEDITION EDDIE BAUER. WHILE DRIVING APPROXIMATELY 45 MPH, THE CONTACT STATED THAT THE VEHICLE STALLED, WHEN THE ELECTRONIC THROTTLE CONTROL WARNING LIGHT ILLUMINATED CAUSING THE VEHICLE TO LOOSE POWER. THE DEALER WAS NOTIFIED AND INFORMED THE CONTACT THAT THERE WERE NO RECALLS AND OFFERED NO F…
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TL*THE CONTACT OWNS A 2005 FORD EXPEDITION EDDIE BAUER. WHILE DRIVING APPROXIMATELY 45 MPH, THE CONTACT STATED THAT THE VEHICLE STALLED, WHEN THE ELECTRONIC THROTTLE CONTROL WARNING LIGHT ILLUMINATED CAUSING THE VEHICLE TO LOOSE POWER. THE DEALER WAS NOTIFIED AND INFORMED THE CONTACT THAT THERE WERE NO RECALLS AND OFFERED NO FURTHER ASSISTANCE. THE MANUFACTURER WAS INFORMED AND ADVISED THE CONTACT THAT THEY WERE NOT AWARE OF THE PROBLEM AND TO FILE A COMPLAINT WITH NHTSA. THE MANUFACTURER ALSO STATED THAT THEY WOULD DOCUMENT THE COMPLAINT AS WELL. THE VEHICLE WAS NOT REPAIRED. THE CURRENT AND FAILURE MILEAGES WERE APPROXIMATELY 58,000. UPDATED 07/18/11
NHTSA ODI #10370958
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