NHTSA owner reports · September 18, 2026 snapshot.
What owners actually said
315 reports200,000 miles · Oct 7, 2016
Electrical SystemCrash
SAME AS EVERYONE ELSE DRIVING NORMALLY AND TRUCK COMPLETELY SHUTS OFF 4 DIFFERENT TIMES ALL DIFFERENTLY I CHANGED THE FUEL PUMP DRIVER MODULE HAD FUEL TANK DROPPED AND CHANGED FUEL FILTER AND PUMP I'M NOT GOING TO LIE I LOVE MY BABY SHE'S BEEN GOOD TO ME BESIDES THIS I HAVE 250,000 PLUS MILES ON HER AND COUNTING AND NEVER FACED …
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SAME AS EVERYONE ELSE DRIVING NORMALLY AND TRUCK COMPLETELY SHUTS OFF 4 DIFFERENT TIMES ALL DIFFERENTLY I CHANGED THE FUEL PUMP DRIVER MODULE HAD FUEL TANK DROPPED AND CHANGED FUEL FILTER AND PUMP I'M NOT GOING TO LIE I LOVE MY BABY SHE'S BEEN GOOD TO ME BESIDES THIS I HAVE 250,000 PLUS MILES ON HER AND COUNTING AND NEVER FACED PROBS TILL NOW I'VE RECENTLY THIS YEAR (TECHNICALLY) REBUILT HER MOTOR AND THAT'S IT . ALSO PASSANGER OVER HEAD LIGHTSTART HAVE BEEN ACTING FUNNY SOME WORK SOME DON'T AND AC IN THE 3RD ROW SOMETIMES GOES OUT OR MAKES A CLICKING NOISE AND HEATER DON'T WORK AT ALL ON THE 2ND OR 3RD ROW I AM A SINGLE FEMALE WITH 3 YOUNG KIDS ID LOVE TO KEEP MY BABY RUNNING SO PLEASE HELP AND I'VE HAD ONE OTHER PROB ONE TIME ON HIGH WAY I HAD A FENDER BENDER I REPEATEDLY STOPPED OVER N OVER ON BREAKS AND NEVER MANAGED TO STOP UNTIL I SLAMMED INTO OTHER DRIVER IN FRONTHE OF ME ME AND MY KIDS WERE TERRIFIED AND NEVER THANK GOD HAPPENED AGAIN BUT YEP SO PLEASE FOR THE LOVE OF PEOPLE'S SAFETY RECALL FIX AND APOLOGIZE FOR THE WRONG HARMFUL DOING LIKE BIG BOYS AND PAY UP OR YOU'LL EITHER LOSE PRECIOUS INNOCENT LIVES OF FORD CUSTOMERS OR JUST LOSE CUSTOMERS IN GENERAL HAVE A HEART FIX YALLS WRONG AND LETS MOVE ON WITH THIS FORD BUILT TUFF HECK OF A BEAUTIFUL SUV AND LETS LIVE LIFE SAFE TY SORRY FOR THE CAPS NOT YELLING JUST NEEDING TO STAND OUT IS ALL TEXAS IS WHERE I'M AT YALL BE SAFE ;)
NHTSA ODI #10914398
186,000 miles · Sep 27, 2016
Power TrainVehicle Speed ControlWheels
I HAVE AN 05 EXPEDITION EDDIE BAUER EDITION AND THE TRUCK WAS SHUDDERING AND VIBRATING WHILE ON INCLINE OR DRIVING. IT ALSO WOULD HESITATE UPON ACCELERATION. THE NEXT DAY THE TRUCK WILL ONLY ROLL IN REVERSE IT WILL NOT DRIVE FORWARD AND THE "CHECK ELECTRONIC THROTTLE CONTROL" MESSAGE CONTINUES TO POP UP. DROVE IT AND ALL OF A SU…
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I HAVE AN 05 EXPEDITION EDDIE BAUER EDITION AND THE TRUCK WAS SHUDDERING AND VIBRATING WHILE ON INCLINE OR DRIVING. IT ALSO WOULD HESITATE UPON ACCELERATION. THE NEXT DAY THE TRUCK WILL ONLY ROLL IN REVERSE IT WILL NOT DRIVE FORWARD AND THE "CHECK ELECTRONIC THROTTLE CONTROL" MESSAGE CONTINUES TO POP UP. DROVE IT AND ALL OF A SUDDEN IT WOULDN'T SHIFT, AND ALL GAUGES WENT FLAT, TRUCK WAS STILL REVVING BUT GAUGES WERE AT ZERO AND THE TRUCK WOULDN'T MOVE. I WAS GOING 60 MPH. AND IT JUST STOPPED MOVING COMPLETELY. CANNOT DRIVE THE TRUCK.
NHTSA ODI #10910103
112,000 miles · Jul 1, 2016
Engine
MY ENGINE SAID FAIL SAFE MODE. MY SPARK PLUGS GOT STUCK IN ENGINE COSTING ME 1000 TO FIX.
NHTSA ODI #10881950
123,000 miles · Jun 26, 2016
Service Brakes
WAS DRIVING AND EXPERIENCED COMPLETE BRAKE FAILURE, NO WARNING, WENT TO STOP AND HAD NO BRAKES WHAT SO EVER! THE BRAKE LINE GOING TO THE PASSENGER SIDE FRONT CALIPER HAD COMPLETELY RUSTED AWAY UNDER THE MIDDLE OF THE VEHICLE BETWEEN THE PASSENGER SIDE FRONT TIRE AND THE ABS DISTRIBUTION BOX. I WAS ALWAYS TOLD THAT THE BRAKE SYST…
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WAS DRIVING AND EXPERIENCED COMPLETE BRAKE FAILURE, NO WARNING, WENT TO STOP AND HAD NO BRAKES WHAT SO EVER! THE BRAKE LINE GOING TO THE PASSENGER SIDE FRONT CALIPER HAD COMPLETELY RUSTED AWAY UNDER THE MIDDLE OF THE VEHICLE BETWEEN THE PASSENGER SIDE FRONT TIRE AND THE ABS DISTRIBUTION BOX. I WAS ALWAYS TOLD THAT THE BRAKE SYSTEMS WERE DESIGNED WITH A TANDEM MASTER CYLINDER SO THAT IF AN EVENT LIKE THIS HAPPENED YOU WOULD STILL HAVE 2 WHEELS THAT HAD BRAKES. THIS OBVIOUSLY IS NOT THE CASE AS THERE WAS A COMPLETE LOSS OF ALL 4 BRAKES. LUCKILY I WAS ONLY DOING 25 MPH AND THERE WAS NO TRAFFIC WHERE I WAS WHEN THIS HAPPENED, IT TOOK A WAYS TO GET THE VEHICLE STOPPED BY APPLYING THE PARKING BRAKE. I DON'T WANT TO EVEN THINK WHAT WOULD HAPPEN IF I WAS ON THE FREEWAY DOING 70 MPH AND HAD TO STOP IN AN EMERGENCY AND THIS HAPPENED, I WOULD PROBABLY BE DEAD AND POSSIBLY SOMEONE ELSE ALSO. THIS NEEDS TO BE ADDRESSED ASAP. PEOPLES LIVES ARE AT SERIOUS RISK HERE. I CANNOT UNDERSTAND WHY THESE BRAKE LINES WOULD NOT BE MADE OUT OF 318 STAINLESS STEEL, THEY WOULD NEVER CORRODE AND THIS WOULD POSSIBLY SAVE LIVES. I AM TOTALLY CONVINCED THAT PEOPLE HAVE DIED FROM THIS HAPPENING. THIS IS NOTHING NEW WITH FORDS! MY MECHANIC TOLD ME THAT HE SEES FORD VEHICLES ALL THE TIME WITH RUSTED OUT BRAKE LINES AND PEOPLE THAT HAVE EXPERIENCED COMPLETE BRAKE FAILURE DUE TO THIS.
NHTSA ODI #10876646
120,000 miles · Jun 25, 2016
EngineVehicle Speed Control
MY 2005 EXPEDITION IS MAINTAINED NORMALLY AND SPARK PLUGS CHANGED AND THE ENGINE WILL EITHER CUT OFF OR SLOW DOWN TO ABOUT 30 MILES AN HOUR WHILE I AM ON THE HIGHWAY WITH A ERROR MESSAGE FAIL SAVE MODE. MOST TIMES WHEN I SHUT OFF THE ENGINE AND RESTART IT TURNS OVER BUT DOESN'T STAY ON. TOTALLY UNSAFE FOR ME AND MY FAMILY. PLEAS…
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MY 2005 EXPEDITION IS MAINTAINED NORMALLY AND SPARK PLUGS CHANGED AND THE ENGINE WILL EITHER CUT OFF OR SLOW DOWN TO ABOUT 30 MILES AN HOUR WHILE I AM ON THE HIGHWAY WITH A ERROR MESSAGE FAIL SAVE MODE. MOST TIMES WHEN I SHUT OFF THE ENGINE AND RESTART IT TURNS OVER BUT DOESN'T STAY ON. TOTALLY UNSAFE FOR ME AND MY FAMILY. PLEASE RESEARCH AND RECALL WHAT THE ISSUE IS! THIS ISSUE HAS STARTED ABOUT 4 YEARS AFTER WE PURCHASED THE VEHICLE AND HAS BEEN HAPPENING MAYBE ONE TO TWO TIMES A MONTH SINCE.
NHTSA ODI #10876578
Mileage unknown · Jun 13, 2016
EngineFuel/propulsion System
FOR MANY TIME THAT MY EXPEDITION HAS STALLED BECAUSE OF THE THROTTLE BODY FAILING. THE ENGINE GOES INTO SAFE MODE AND STALLS AND STOPS, THI IS VERY DANGER SITUATION
NHTSA ODI #10873914
Mileage unknown · May 3, 2016
Fuel/propulsion SystemPower TrainStructure
TRANSMISSION BAD ,PAINT COME OUT SOME AREAS, REPLACE ALL THE SPARK PLUGS
NHTSA ODI #10862924
118,000 miles · Apr 11, 2016
Electrical SystemVisibility
TL* THE CONTACT OWNS A 2005 FORD EXPEDITION. THE CONTACT STATED THAT THE AIR CONDITIONING UNIT FAILED AND EMITTED HOT AIR FROM THE VENTS WHEN ACTIVATED. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC SEVERAL TIMES WHERE THE BLENDER DOOR ACTUATOR, COMPRESSOR, AND CONTROL PANEL WERE REPLACED; HOWEVER, THE FAILURE RECURRED. THE M…
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TL* THE CONTACT OWNS A 2005 FORD EXPEDITION. THE CONTACT STATED THAT THE AIR CONDITIONING UNIT FAILED AND EMITTED HOT AIR FROM THE VENTS WHEN ACTIVATED. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC SEVERAL TIMES WHERE THE BLENDER DOOR ACTUATOR, COMPRESSOR, AND CONTROL PANEL WERE REPLACED; HOWEVER, THE FAILURE RECURRED. THE MECHANIC STATED THAT THE FAILURE COULD NOT BE REMEDIED. THE MANUFACTURER STATED THAT THERE WERE NO RECALLS FOR THE VEHICLE. THE CONTACT WAS ALSO ADVISED THAT THE FAILURE COULD HAVE BEEN ATTRIBUTED TO THE CONTROL HEAD THAT WAS LOCATED BEHIND THE CONTROL PANEL. THE VEHICLE WAS NOT REPAIRED. THE VIN WAS UNKNOWN. THE FAILURE MILEAGE WAS 118,000.
NHTSA ODI #10854874
20 miles · Mar 28, 2016
Electrical SystemElectronic Stability Control (esc)Engine
I HAVE A 2005 FORD EXPEDITION AND HAVE MAINTAINED MY VEHICLE MAINTENANCE AND ONLY HAVE 124,000 MILES ON THIS VEHICLE. IT CONTINUES TO SHUT OFF THE ENGINE AND CODE FAIL SAFE MODE ON CODE APPEAR AND WHEN I'M DRIVING ON THE HIGHWAY IT IS DANGEROUS. AFTER READING SO MANY COMPLAINTS THIS IS UNSAFE. ALSO, THE COMPUTER ISSUES WITH …
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I HAVE A 2005 FORD EXPEDITION AND HAVE MAINTAINED MY VEHICLE MAINTENANCE AND ONLY HAVE 124,000 MILES ON THIS VEHICLE. IT CONTINUES TO SHUT OFF THE ENGINE AND CODE FAIL SAFE MODE ON CODE APPEAR AND WHEN I'M DRIVING ON THE HIGHWAY IT IS DANGEROUS. AFTER READING SO MANY COMPLAINTS THIS IS UNSAFE. ALSO, THE COMPUTER ISSUES WITH LOCKING DOORS, FAILURE OF THE TRANSMISSION (WHICH I HAD TO REPLACE) SUCH A DISAPPOINTMENT OF A VEHICLE. FORD SHOULD RECALL ENGINE AND COMPUTER ISSUES. I PURCHASED THIS VEHICLE BRAND NEW $50,000 + AND HAVE NOT BE ABLE TO DEPEND ON THE STABILITY SINCE I'VE HAD IT.
NHTSA ODI #10852059
65,000 miles · Aug 16, 2015
Engine
MY FORD EXPEDITION, WHILE DRIVING AT 40 MILES AN HOUR LOST POWER. THIS IS THE 3RD TIME IN 2 YEARS IT HAS HAPPENED. ON THE INFO CENTER IT STATED ENGINE FAIL SAFE MODE. THE THREE TIMES IT HAS HAPPENED HAS BEEN ON BACK ROADS.I CONSIDER THIS A VERY UNSAFE CONDITION . MY DEALER LOOKED AT IT THE FIRST TWO TIMES AND SAID THERE WERE NO …
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MY FORD EXPEDITION, WHILE DRIVING AT 40 MILES AN HOUR LOST POWER. THIS IS THE 3RD TIME IN 2 YEARS IT HAS HAPPENED. ON THE INFO CENTER IT STATED ENGINE FAIL SAFE MODE. THE THREE TIMES IT HAS HAPPENED HAS BEEN ON BACK ROADS.I CONSIDER THIS A VERY UNSAFE CONDITION . MY DEALER LOOKED AT IT THE FIRST TWO TIMES AND SAID THERE WERE NO CODES, THAT I WOULD NEED TO BRING IT IN SOONER. BUT THERE ARE NO LASTING RESULTS, AND IT STARTS RIGHT BACK UP.
NHTSA ODI #10748973
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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