NHTSA owner reports · September 18, 2026 snapshot.
Electrical System complaints
32 reportsClear category filter222,000 miles · Apr 21, 2023
Air BagsElectrical SystemPower TrainCrashInjury
The contact owns a 2006 Ford Expedition. The contact stated that while driving at a low rate of speed, the vehicle would independently accelerate upon depression of the accelerator pedal without warning. During a recent failure, the contact crashed into a fence as part of the fence had become wedged underneath the vehicle. Afte…
Read full complaint
The contact owns a 2006 Ford Expedition. The contact stated that while driving at a low rate of speed, the vehicle would independently accelerate upon depression of the accelerator pedal without warning. During a recent failure, the contact crashed into a fence as part of the fence had become wedged underneath the vehicle. After placing the vehicle into park and exiting the vehicle, the wheels continued to move. The air bags did not deploy upon impact. Despite minor soreness to his neck, no medial attention was required. A police report was not filed. Despite the failure, the contact managed to restart the vehicle and safely to his destination. The fence sustained severe damage as a result of the failure. The dealer nor the manufacturer had yet to be notified of the failure. The vehicle had yet to be diagnosed or repaired. The failure mileage was approximately 220,000.
NHTSA ODI #11518263
245,000 miles · Jul 15, 2019
Electrical SystemEngine
TL* THE CONTACT CALLED ON BEHALF OF THE OWNER OF A 2006 FORD EXPEDITION. WHEN THE VEHICLE WAS STARTED, THERE WAS AN ODOR OF ANTIFREEZE IN THE VEHICLE. ADDITIONALLY, THE TEMPERATURE GAUGE AND CYLINDER HEAD TEMPERATURE SWITCH BECAME INOPERABLE. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO DIAGNOSED THAT THE INTAKE MANIFOLD…
Read full complaint
TL* THE CONTACT CALLED ON BEHALF OF THE OWNER OF A 2006 FORD EXPEDITION. WHEN THE VEHICLE WAS STARTED, THERE WAS AN ODOR OF ANTIFREEZE IN THE VEHICLE. ADDITIONALLY, THE TEMPERATURE GAUGE AND CYLINDER HEAD TEMPERATURE SWITCH BECAME INOPERABLE. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO DIAGNOSED THAT THE INTAKE MANIFOLD AND CYLINDER HEAD TEMPERATURE SWITCH NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE DEALER WAS NOT CONTACTED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 245,000.
NHTSA ODI #11232007
Mileage unknown · Jan 12, 2018
Electrical SystemEngineVehicle Speed Control
TAMARA RECALL
NHTSA ODI #11062497
117,000 miles · Apr 11, 2017
Electrical SystemEngine
WHILE IN TRAFFIC, AT LEAST 100 TIMES IN THE LAST FOUR YEARS (AT VARIABLE SPEEDS FROM 5 TO 65 MPH ON CITY STREETS AND FREEWAYS) MOST RECENTLY TWICE IN THE LAST WEEK, THE RPMS DROP BELOW 500 AND THE VEHICLE DIES AND "ENGINE FAILSAFE MODE" LIGHTS UP ON THE DASH. I HAVE TO EITHER COAST TO PULL OVER OR DEAD STOP IN THE MIDDLE OF THE …
Read full complaint
WHILE IN TRAFFIC, AT LEAST 100 TIMES IN THE LAST FOUR YEARS (AT VARIABLE SPEEDS FROM 5 TO 65 MPH ON CITY STREETS AND FREEWAYS) MOST RECENTLY TWICE IN THE LAST WEEK, THE RPMS DROP BELOW 500 AND THE VEHICLE DIES AND "ENGINE FAILSAFE MODE" LIGHTS UP ON THE DASH. I HAVE TO EITHER COAST TO PULL OVER OR DEAD STOP IN THE MIDDLE OF THE ROAD. I HAVE TO TURN THE VEHICLE COMPLETELY OFF (EVEN THOUGH IN FAILSAFE MODE ENGINE IS OFF, THE ELECTRONICS ARE STILL ON) AND THEN RESTART AND THEN IT WILL DRIVE JUST FINE UNTIL IT HAPPENS AGAIN. IT HAPPENS ANYWHERE FROM ONCE EVERY 6 MONTHS TO 6 TIMES IN 1 WEEK. IT SEEMS AS THOUGH IF I DRIVE WITH BOTH FEET IN TRAFFIC AND MAINTAIN ABOUT 800-1000 RMPS AT ALL TIMES IT DOESN'T DO THIS, HOWEVER THIS CANNOT BE DONE ALL THE TIME ESPECIALLY WHEN TRYING TO STOP THE LARGE VEHICLE QUICKLY OR TURNING IN AN INTERSECTION. NOTHING HAS BEEN DIAGNOSED BY DEALERSHIP AS NO CODES ARE THROWN. I ALSO OWN A OBD2 READER AND NO CODES HAVE EVER LISTED UNLESS ITS TIME TO CHANGE THE SPARK PLUGS. SEVERAL DIFFERENT MECHANICS, FORUMS AND BRAINSTORMING HAS NOT FIGURED IT OUT. I HAVE REPLACED MOSTLY EVERYTHING WITH EXCEPTION TO A NEW TRANSMISSION AND COMPUTER. MOSTLY EVERYTHING INCLUDING WIRES AND VACUUM LINES AND GASKETS HAVE BEEN REPLACED DUE TO MAINTENANCE OR REPAIRS FROM EVERYTHING ELSE THAT HAS GONE WRONG WITH IT. I HAVE PUT ABOUT $10K INTO NEW PARTS FOR THIS VEHICLE. I BOUGHT IT WITH 60K MILES ON IT AND IT NOW HAS 117K, ITS A DAILY DRIVER WITH 28 MILES OF TRAVEL 5 DAYS A WEEK. ALSO THE ONLY VEHICLE THAT FITS ALL OF THE CHILDREN FOR SOCCER, TRACK AND VOLLEYBALL TRAVELING TOURNAMENTS/GAMES. LUCKILY IT DOESN'T HAPPEN VERY OFTEN WHEN I'M NOT IN TRAFFIC SO THE KIDS AREN'T USUALLY WITH ME BUT IT IS VERY SCARY NOT TO KNOW IF YOU ARE GOING TO STOP OR IF THE PEOPLE BEHIND YOU ARE GOING TO HIT YOU OR NOT.
NHTSA ODI #10971943
140,000 miles · Jun 29, 2016
Electrical SystemEngine
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT THE ENGINE FAIL SAFE MODE WARNING LIGHT FLASHED AND THE VEHICLE DRASTICALLY REDUCED SPEED AND STALLED WITHOUT WARNING. THE CONTACT HAD TO APPLY FORCE TO COAST THE VEHICLE OFF THE ROAD. THE VEHICLE WAS TOWED TO AN INDEPENDENT MECHANIC WHERE IT WAS DIAGNOSED THAT…
Read full complaint
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT THE ENGINE FAIL SAFE MODE WARNING LIGHT FLASHED AND THE VEHICLE DRASTICALLY REDUCED SPEED AND STALLED WITHOUT WARNING. THE CONTACT HAD TO APPLY FORCE TO COAST THE VEHICLE OFF THE ROAD. THE VEHICLE WAS TOWED TO AN INDEPENDENT MECHANIC WHERE IT WAS DIAGNOSED THAT THE COMPUTER NEEDED TO BE REPLACED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE VIN WAS NOT AVAILABLE. THE APPROXIMATE FAILURE MILEAGE WAS 140,000.
NHTSA ODI #10881519
130,000 miles · Nov 16, 2015
Electrical SystemEngineSteering
I WAS DRIVING DOWN THE FREEWAY APPROXIMATELY 50 MPH WHEN MY ENGINE COMPLETELY SHUT DOWN. THERE WAS A BEEP AND A LIGHT CAME ON THAT SAID "ENGINER FAIL SAFE MODE". THE ENGINE SHUT OFF, BUT LUCKILY I STILL HAD FULL MOVEMENT OF MY STEERING WHEEL SO I WAS ABLE TO CHANGE LANES AND GET OFF TO THE SHOULDER. I PANICKED FOR A MOMENT, B…
Read full complaint
I WAS DRIVING DOWN THE FREEWAY APPROXIMATELY 50 MPH WHEN MY ENGINE COMPLETELY SHUT DOWN. THERE WAS A BEEP AND A LIGHT CAME ON THAT SAID "ENGINER FAIL SAFE MODE". THE ENGINE SHUT OFF, BUT LUCKILY I STILL HAD FULL MOVEMENT OF MY STEERING WHEEL SO I WAS ABLE TO CHANGE LANES AND GET OFF TO THE SHOULDER. I PANICKED FOR A MOMENT, BUT STARTED THE CAR AND IT STARTED RIGHT BACK UP. I ATTEMPTED MY DRIVE TO WORK AND MADE IT THERE. NOT SURE WHAT TO DO ABOUT THE PROBLEM, BUT I'M SCARED TO DRIVE IT ANYMORE. ESPECIALLY WITH MY CHILDREN IN THE VEHICLE AND MY HUSBAND IS OUT OF TOWN FOR WORK. THIS IS A MAJOR SAFETY ISSUE AND NEEDS TO BE RECALLED.
NHTSA ODI #10790557
140,000 miles · Sep 29, 2015
Electrical SystemSteeringVehicle Speed Control
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT THE VEHICLE STALLED. ON ANOTHER OCCASION, THE VEHICLE STALLED AFTER THE VEHICLE ENGINE SAFETY MODE WAS INITIATED WHILE DRIVING APPROXIMATELY 5 MPH. THE VEHICLE WAS RESTARTED BUT THE FAILURE RECURRED FIVE MINUTES LATER. THE VEHICLE WAS TAKEN TO A DEALER WHERE IT…
Read full complaint
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT THE VEHICLE STALLED. ON ANOTHER OCCASION, THE VEHICLE STALLED AFTER THE VEHICLE ENGINE SAFETY MODE WAS INITIATED WHILE DRIVING APPROXIMATELY 5 MPH. THE VEHICLE WAS RESTARTED BUT THE FAILURE RECURRED FIVE MINUTES LATER. THE VEHICLE WAS TAKEN TO A DEALER WHERE IT WAS DIAGNOSED THAT THE THROTTLE BODY SENSOR NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 140,000.
NHTSA ODI #10778348
135,000 miles · May 1, 2015
Electrical SystemEngine
FIRST OCCURRENCE EXHIBITED FLICKERING DASHBOARD LIGHTS BEFORE THE ELECTRICAL SYSTEM WENT COMPLETELY DEAD AND THE ENGINE QUIT WHILE ACCELERATING AT APPROXIMATELY 20 MPH. PUT VEHICLE IN NEUTRAL AND WAS ABLE TO RESTART ENGINE NORMALLY BEFORE COMING TO A STOP. HAVE EXPERIENCED SEVERAL SHORT INSTANCES OF DASH FLICKERING OVER THE PA…
Read full complaint
FIRST OCCURRENCE EXHIBITED FLICKERING DASHBOARD LIGHTS BEFORE THE ELECTRICAL SYSTEM WENT COMPLETELY DEAD AND THE ENGINE QUIT WHILE ACCELERATING AT APPROXIMATELY 20 MPH. PUT VEHICLE IN NEUTRAL AND WAS ABLE TO RESTART ENGINE NORMALLY BEFORE COMING TO A STOP. HAVE EXPERIENCED SEVERAL SHORT INSTANCES OF DASH FLICKERING OVER THE PAST COUPLE OF WEEKS WITH NO APPARENT ENGINE PROBLEMS. DURING THAT SAME PERIOD THERE HAVE BEEN APPROXIMATELY 4 INSTANCES OF THE ELECTRICAL SYSTEM BEING COMPLETELY DEAD UPON THE INITIAL ATTEMPT TO START THE ENGINE. WHEN THIS HAPPENS, THE ONLY LIGHT THAT IS ILLUMINATED ON THE DASH (OR ANYWHERE ELSE FOR THAT MATTER) IS WHAT I THINK IS THE AIRBAG LIGHT; HOWEVER, NORMAL ELECTRICAL POWER HAS, THUS FAR, RE-APPEARED WITHIN 5 MINUTES AND THE ENGINE THEN STARTS AND RUNS NORMALLY. YESTERDAY THE "CHECK ENGINE" LIGHT CAME ON AND I WAS ABLE TO PULL A CODE OF P0119 (ENGINE COOLANT TEMPERATURE CIRCUIT INTERMITTENT) UPON RETURNING HOME. I SUBSEQUENTLY CLEARED THE CODE, BUT THE READER INDICATES ANOTHER CODE IS "PENDING". I BELIEVE THIS IS A SYMPTOM OF A LARGER PROBLEM. I HAVE NOT EXPERIENCED A "ENGINE FAILSAFE MODE" WARNING MESSAGE, BUT THIS COMPLAINT IS VERY SIMILAR TO MANY OTHERS ALREADY POSTED AND I AGREE WITH THE RELATED SAFETY CONCERNS AND NEED FOR A RECALL. *TR
NHTSA ODI #10714028
135,000 miles · Jan 15, 2015
Electrical System
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 20 MPH, THE VEHICLE STALLED WITHOUT WARNING. IN ADDITION, THE FAIL SAFE WARNING LIGHT ILLUMINATED. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 135,000…
Read full complaint
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 20 MPH, THE VEHICLE STALLED WITHOUT WARNING. IN ADDITION, THE FAIL SAFE WARNING LIGHT ILLUMINATED. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 135,000.
NHTSA ODI #10672818
Mileage unknown · Dec 31, 2014
Electrical SystemEngine
ENGINE FREQUENTLY GOES IN TO ENGINE FAILSAFE MODE. THIS HAPPENS TYPICALLY WHEN THE CAR IS BEING LIGHTLY THROTTLED SUCH AS AROUND CORNERS OR IN RUSH HOUR TRAFFIC. THE CAR RESTARTS FINE, BUT MUST BE COMPLETELY TURNED OFF, WHICH DISABLES AIRBAGS, MAKES POWER STEERING AND POWER BRAKES IMPOSSIBLE TO USE. PREVIOUSLY I HAVE CLEANED …
Read full complaint
ENGINE FREQUENTLY GOES IN TO ENGINE FAILSAFE MODE. THIS HAPPENS TYPICALLY WHEN THE CAR IS BEING LIGHTLY THROTTLED SUCH AS AROUND CORNERS OR IN RUSH HOUR TRAFFIC. THE CAR RESTARTS FINE, BUT MUST BE COMPLETELY TURNED OFF, WHICH DISABLES AIRBAGS, MAKES POWER STEERING AND POWER BRAKES IMPOSSIBLE TO USE. PREVIOUSLY I HAVE CLEANED THE THROTTLE BODY OF THE CAR AT THE SUGGESTION OF NUMEROUS MECHANICS, AND THIS RESOLVED THE ISSUE FOR NEARLY A YEAR. NOW THE PROBLEM IS BACK AGAIN. I'M CONCERNED FOR MY WIFE'S SAFETY. THE THROTTLE BODY NEEDS TO BE REDESIGNED AS THE THROTTLE PLATE STICKING RETURNING INVALID DATA TO THE COMPUTER SENDING THE ENGINE INTO FAILSAFE MODE. *JS
NHTSA ODI #10669324
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
Illustration