NHTSA owner reports · September 18, 2026 snapshot.
What owners actually said
315 reports122,000 miles · Apr 4, 2014
Fuel/propulsion SystemVehicle Speed Control
WHILE SETTING AT A STOP LIGHT A WARNING MESSAGE CAME ON ABOUT CHECKING ELECTRONIC THROTTLE CONTROL. WHEN I RELEASE THE BRAKE TO ACCELERATE WHEN THE LIGHT TURNED GREEN I COASTED INTO THE INTERSECTION ONLY TO FIND THAT THE ACCELERATOR PEDDLE HAD NO RESPONSE. FORTUNATELY THE ENGINE IDLE WAS ENOUGH TO GET ME THROUGH THE INTERSECTION…
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WHILE SETTING AT A STOP LIGHT A WARNING MESSAGE CAME ON ABOUT CHECKING ELECTRONIC THROTTLE CONTROL. WHEN I RELEASE THE BRAKE TO ACCELERATE WHEN THE LIGHT TURNED GREEN I COASTED INTO THE INTERSECTION ONLY TO FIND THAT THE ACCELERATOR PEDDLE HAD NO RESPONSE. FORTUNATELY THE ENGINE IDLE WAS ENOUGH TO GET ME THROUGH THE INTERSECTION BEFORE THE LIGHT TURNED RED. I THEN COASTED TO THE NEAREST PARKING LOT AND SHUT THE ENGINE OFF. RESTARTED THE VEHICLE WITH NO CHANGE IN ACCELERATOR PEDDLE RESPONSE. AFTER DOING RESEARCH AND SEEING NUMEROUS PROBLEMS WITH THIS SAME ISSUE I SEE I WAS FORTUNATE TO HAVE NOT BEEN DRIVING AT HIGHWAY SPEEDS WHEN THIS ISSUE HAPPEN. FORD NEEDS TO RECALL AND FIX THIS ISSUE BEFORE SOMEONE GETS KILLED WHEN THEIR VEHICLE JUST QUITS WORKING. *TR
NHTSA ODI #10577352
67,000 miles · Apr 2, 2014
Service Brakes
I HAVE TALKED TO A FEW OTHER OWNERS OF FORD EXPEDITIONS (LATER MODELS 2004-2008) AND THERE IS A DEFINITE ISSUE WITH RUST AND OTHER COMPONENTS RUSTING OUT. IT SEEMS TO BE A SERIOUS ISSUE WITH RUST ESP WHEN THE BRAKE LINES ARE BASICALLY ALL RUSTED OUT IN THE FRONT OF THE VEHICLE. ALSO THE CROSS MEMBER FRAME UNDERNEATH HAS A LOT MO…
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I HAVE TALKED TO A FEW OTHER OWNERS OF FORD EXPEDITIONS (LATER MODELS 2004-2008) AND THERE IS A DEFINITE ISSUE WITH RUST AND OTHER COMPONENTS RUSTING OUT. IT SEEMS TO BE A SERIOUS ISSUE WITH RUST ESP WHEN THE BRAKE LINES ARE BASICALLY ALL RUSTED OUT IN THE FRONT OF THE VEHICLE. ALSO THE CROSS MEMBER FRAME UNDERNEATH HAS A LOT MORE THAN ACCEPTABLE AMOUNT OF RUST, NEVER SEEN THIS MUCH EVEN WITH A TRUCK I HAVE NOW A 1997 DODGE WITH 190,000 MILES DOESN'T EVEN COME CLOSE TO THE RUST I SEE WITH THE FORD. RUST BUBBLES ON THE REAR LIFT GATE HANDLE AREA AND JUST ABOUT ALL AROUND THE WINDOW AREAS AND THE HOOD. MIND YOU THAT THE TIME WE'VE HAD THE VEHICLE ONLY MAYBE A HANDFUL OF TIMES IT WAS OUT IN SNOW OR EVEN RAINY WEATHER - LOW MILES FOR THE YEAR 67,000/8 YEARS+. THE LINES AND RUST REPAIR WILL COST MONEY $$ TO FIX I BELIEVE THAT FORD KNOWS THERE'S AN ISSUE AND STIFFS THE CONSUMER KNOWING THAT THE MATERIALS RUST OUT CAUSING A VERY UNSAFE VEHICLE TO DRIVE. ANYBODY FOR A CLASS ACTION LAWSUIT HERE? *TR
NHTSA ODI #10576581
Mileage unknown · Mar 31, 2014
Service Brakes
I HAVE A 2005 FORD EXPEDITION WITH ADJUSTABLE HEIGHT OF THE BRAKE PEDDLE. THE ADJUSTMENT DOES NOT WORK AND THE HEIGHT OF THE BRAKE PEDDLE IS AT A HEIGHT THAT WHEN THE BRAKE IS DEPRESSED IT IS ALSO POSSIBLE THAT THE ACCELERATOR IS ALSO DEPRESSED CAUSING UNEXPECTED ACCELERATION. I HAVE CONTACTED MY LOCAL DEALER AND WWW.FORD.COM AB…
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I HAVE A 2005 FORD EXPEDITION WITH ADJUSTABLE HEIGHT OF THE BRAKE PEDDLE. THE ADJUSTMENT DOES NOT WORK AND THE HEIGHT OF THE BRAKE PEDDLE IS AT A HEIGHT THAT WHEN THE BRAKE IS DEPRESSED IT IS ALSO POSSIBLE THAT THE ACCELERATOR IS ALSO DEPRESSED CAUSING UNEXPECTED ACCELERATION. I HAVE CONTACTED MY LOCAL DEALER AND WWW.FORD.COM ABOUT THIS SAFETY ISSUE AND BOTH HAVE TOLD ME THAT THERE IS NO RECALL AND THAT THEY WILL NOT FIX OR ASSIST ME ON THIS. I BELIEVE THAT THE SUDDEN ACCELERATION IS A SERIOUS SAFETY CONCERN AND SHOULD BE ADDRESSED BY NHTSA. *TR
NHTSA ODI #10575920
83,000 miles · Mar 23, 2014
Vehicle Speed Control
AFTER STOPPING AT A TRAFFIC SIGNAL, THE ENGINE BEGAN TO ACCELERATE WITHOUT THE PEDAL BEING PUSHED. THE FOOT BRAKE WAS APPLIED WITH INCREASING FORCE TO STOP THE VEHICLE FROM GOING INTO THE INTERSECTION. THIS SLOWED THE FORWARD MOVEMENT OF THE VEHICLE DOWN, BUT DIDN'T STOP IT UNTIL THE IGNITION WAS TURNED OFF. THE VEHICLE WAS R…
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AFTER STOPPING AT A TRAFFIC SIGNAL, THE ENGINE BEGAN TO ACCELERATE WITHOUT THE PEDAL BEING PUSHED. THE FOOT BRAKE WAS APPLIED WITH INCREASING FORCE TO STOP THE VEHICLE FROM GOING INTO THE INTERSECTION. THIS SLOWED THE FORWARD MOVEMENT OF THE VEHICLE DOWN, BUT DIDN'T STOP IT UNTIL THE IGNITION WAS TURNED OFF. THE VEHICLE WAS RESTARTED WITHIN TWO MINUTES AND OPERATED NORMALLY. THIS IS ONE OF THOSE VERY DANGEROUS PROBLEMS THAT CAN CAUSE ACCIDENTS AND GET PEOPLE KILLED. THIS ELECTRONIC THROTTLE CONTROL/BODY NEEDS TO BE RE-ENGINEERED AND A RECALL ISSUED FOR THIS PRODUCT. TOO MANY ISSUES WITH THIS NOT TO IGNORE IT. *TR
NHTSA ODI #10574265
Mileage unknown · Mar 17, 2014
Electrical SystemEngineSteering
VEHICLE DIED UNEXPECTEDLY WHILE TRAVELING DOWN HIGHWAY AT A HIGH RATE OF SPEED. THERE ARE HUNDREDS OF COMPLAINTS JUST LIKE THIS ON HERE. IF A RECALL ISN'T IN ORDER PEOPLE WILL DIE AND THE LAWSUITS WILL BEGIN. IT'S OBVIOUSLY A MAJOR MECHANICAL PROBLEM. FORD AND THE NHTSA SHOULD BE LIABLE. THIS IS SERIOUS AND READING THROUGH A…
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VEHICLE DIED UNEXPECTEDLY WHILE TRAVELING DOWN HIGHWAY AT A HIGH RATE OF SPEED. THERE ARE HUNDREDS OF COMPLAINTS JUST LIKE THIS ON HERE. IF A RECALL ISN'T IN ORDER PEOPLE WILL DIE AND THE LAWSUITS WILL BEGIN. IT'S OBVIOUSLY A MAJOR MECHANICAL PROBLEM. FORD AND THE NHTSA SHOULD BE LIABLE. THIS IS SERIOUS AND READING THROUGH ALL OF THESE COMPLAINTS IT DOESN'T SEEM LIKE THE NHTSA IS DOING THEIR JOB. *TR
NHTSA ODI #10572716
77,000 miles · Mar 2, 2014
Electrical SystemFuel System, GasolineVehicle Speed Control
WHILE DRIVING HOME DOWN A SLIGHT DECLINE, I HEARD A BEEP AND THE MESSAGE ON THE DASH READ (CHECK ELECTRONIC THROTTLE CONTROL) WHICH I THEN MENTALLY ADDED TO MY LIST OF THINGS TO DO. NOT UNTIL A NEEDED TO START ACCELERATING AGAIN DID I REALIZE THAT MY THROTTLE WAS COMPLETELY INOPERABLE. LUCKILY, A WORD USED FREQUENTLY BY OTHER …
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WHILE DRIVING HOME DOWN A SLIGHT DECLINE, I HEARD A BEEP AND THE MESSAGE ON THE DASH READ (CHECK ELECTRONIC THROTTLE CONTROL) WHICH I THEN MENTALLY ADDED TO MY LIST OF THINGS TO DO. NOT UNTIL A NEEDED TO START ACCELERATING AGAIN DID I REALIZE THAT MY THROTTLE WAS COMPLETELY INOPERABLE. LUCKILY, A WORD USED FREQUENTLY BY OTHER OWNERS TO DESCRIBE THIS SAME ISSUE, I WAS ABLE TO COAST TO A STOP WHILE OTHER VEHICLES WENT AROUND ME. TURNING OFF THE VEHICLE AND RESTARTING IT SEEMED TO "RESET" THE THROTTLE CONTROL. I DO NOT TRUST THAT IT WILL BE SAFE TO USE, PARTICULARLY WITH THE WINTER DRIVING CONDITIONS THAT I ENCOUNTER. I HAVE AN APPOINTMENT SCHEDULED FOR MONDAY. WITH ALL THE COMPLAINTS I HAVE SEEN REGARDING THIS SAME ISSUE, I AM SHOCKED THAT MORE ACTION (RECALL) HAS NOT BEEN TAKEN. DOES A CRASH, FIRE, INJURY, OR FATALITY NEED TO OCCUR BEFORE THIS CAN BE TAKEN SERIOUSLY? I AM BAFFLED THAT A WARNING MESSAGE CANNOT BE DISPLAYED IN ADVANCE OF COMPLETE THROTTLE FAILURE CONSIDERING THE POTENTIAL CATASTROPHIC OUTCOMES. THIS VEHICLE WAS INSPECTED/SERVICED NOVEMBER 2013. *TR
NHTSA ODI #10566665
117,000 miles · Feb 27, 2014
Engine
TL* THE CONTACT OWNS A 2005 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING 65 MPH, THE VEHICLE STALLED WITHOUT WARNING. THE WRENCH ICON ILLUMINATED AFTER THE FAILURE OCCURRED. THE CONTACT COASTED ONTO THE SHOULDER AND WAS ABLE TO RESTART THE ENGINE. THE VEHICLE WAS LATER TAKEN TO THE DEALER, WHO PERFORMED A DIAGNOSTIC…
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TL* THE CONTACT OWNS A 2005 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING 65 MPH, THE VEHICLE STALLED WITHOUT WARNING. THE WRENCH ICON ILLUMINATED AFTER THE FAILURE OCCURRED. THE CONTACT COASTED ONTO THE SHOULDER AND WAS ABLE TO RESTART THE ENGINE. THE VEHICLE WAS LATER TAKEN TO THE DEALER, WHO PERFORMED A DIAGNOSTIC AND LOCATED THE FAILURE AT THE THROTTLE. THE THROTTLE WAS REPLACED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE AND CURRENT MILEAGE WAS 117,000.
NHTSA ODI #10566261
108,000 miles · Jan 29, 2014
Fuel/propulsion System
TL* THE CONTACT OWNS A 2005 FORD EXPEDITION. THE CONTACT STATED THAT WHILE TRAVELING 60 MPH, THE VEHICLE SUDDENLY STALLED. THE VEHICLE WAS TAKEN TO A PRIVATE MECHANIC WHERE IT WAS FOUND THAT THE DRIVER FUEL MODULE NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED. THE MANUFACTURER WAS NOT CONTACTED ABOUT THE FAILURE. THE FAILURE M…
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TL* THE CONTACT OWNS A 2005 FORD EXPEDITION. THE CONTACT STATED THAT WHILE TRAVELING 60 MPH, THE VEHICLE SUDDENLY STALLED. THE VEHICLE WAS TAKEN TO A PRIVATE MECHANIC WHERE IT WAS FOUND THAT THE DRIVER FUEL MODULE NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED. THE MANUFACTURER WAS NOT CONTACTED ABOUT THE FAILURE. THE FAILURE MILEAGE WAS APPROXIMATELY 108,000.
NHTSA ODI #10562068
112,550 miles · Jan 24, 2014
Engine And Engine CoolingFuel System, Gasoline
I WAS DRIVING MY 2005 FORD EXPEDITION EDDIE BAUER EDITION WHEN I STARTED TO MAKE A TURN. SUDDENLY THE VEHICLE STOPPED MOVING AND AN INDICATOR LIGHT STATING "ENGINE FAIL SAFE MODE" CAME ON. DURING THE TURN, A VEHICLE WAS COMING TOWARD ME AND I BARELY HAD ENOUGH TIME TO GET MY VEHICLE OUT OF THE LANE BEFORE I GOT HIT. I HAD TO STO…
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I WAS DRIVING MY 2005 FORD EXPEDITION EDDIE BAUER EDITION WHEN I STARTED TO MAKE A TURN. SUDDENLY THE VEHICLE STOPPED MOVING AND AN INDICATOR LIGHT STATING "ENGINE FAIL SAFE MODE" CAME ON. DURING THE TURN, A VEHICLE WAS COMING TOWARD ME AND I BARELY HAD ENOUGH TIME TO GET MY VEHICLE OUT OF THE LANE BEFORE I GOT HIT. I HAD TO STOP MY VEHICLE, PUT IT IN PARK (WHILE SITTING ON THE ROADWAY), SHUT IT OFF, AND RESTART IT BEFORE I COULD MOVE AGAIN. IT RAN FINE FOR A COUPLE OF DAYS AND THEN IT HAPPENED TO ME AGAIN WHILE DRIVING. THIS IS A VERY DANGEROUS SITUATION THAT SHOULD BE LOOKED INTO AND AFTER CHECKING THE INTERNET IT SEEMS THERE ARE LOTS OF PEOPLE WITH THE SAME EXPERIENCES. I TOOK MY VEHICLE TO THE SHOP AND THEY TOLD ME IT WAS THE THROTTLE BODY. AFTER SPENDING $409.00 (BECAUSE OF COURSE IT WAS NOT COVERED BY MY WARRANTY) TO REPAIR IT HOPEFULLY THE PROBLEM MAY BE FIXED. I FIGURED SPENDING THE MONEY WAS BETTER THAN THE OPTION OF POSSIBLY GETTING IN A SERIOUS ACCIDENT AND BEING KILLED IF THE PROBLEM WAS NOT FIXED. SOMEBODY NEEDS TO LOOK INTO THIS PROBLEM WITH THE VEHICLE AND MAKE FORD RESPONSIBLE FOR COSTS SINCE IT IS OBVIOUSLY A DEFECT IN THE VEHICLE. *TR
NHTSA ODI #10561395
78,000 miles · Dec 31, 2013
Electrical SystemEngineVehicle Speed Control
WHILE DRIVING 55MPH ON INTERSTATE 95 IN PHILADELPHIA, PA WITH MY WIFE AND 2 CHILDREN THE VEHICLE STOPPED RUNNING AND I WAS DANGEROUSLY STALLED IN THE MIDDLE OF INTERSTATE 95. THE CHECK ENGINE LIGHT CAME ON AND CHECK ELECTRONIC THROTTLE MESSAGE CAME ON. THIS IS A FAMILY VEHICLE AND MY WIFE AND I REFUSE TO DRIVE IT NOW IN FEAR O…
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WHILE DRIVING 55MPH ON INTERSTATE 95 IN PHILADELPHIA, PA WITH MY WIFE AND 2 CHILDREN THE VEHICLE STOPPED RUNNING AND I WAS DANGEROUSLY STALLED IN THE MIDDLE OF INTERSTATE 95. THE CHECK ENGINE LIGHT CAME ON AND CHECK ELECTRONIC THROTTLE MESSAGE CAME ON. THIS IS A FAMILY VEHICLE AND MY WIFE AND I REFUSE TO DRIVE IT NOW IN FEAR OF THIS INCIDENT OCCURRING AGAIN RESULTING IN DEATH OR SERIOUS INJURY. BASED UPON MY RESEARCH, IT APPEARS TO BE A WELL KNOWN PROBLEM THAT OCCURRED TO THOUSANDS OF FORD EXPEDITION OWNERS. I WOULD APPRECIATE THE PROBLEM BEING ADDRESSED EXPEDITIOUSLY BEFORE PEOPLE ARE KILLED AND/OR INJURED. *TR
NHTSA ODI #10557981
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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