NHTSA owner reports · September 18, 2026 snapshot.
Electrical System complaints
32 reportsClear category filter63,500 miles · Mar 1, 2011
Electrical System
2006 FORD EXPEDITION E.B. AND ENGINE FAILSAFE MODE 1. THE EVENTS LEADING UP TO THE FAILURE: THERE ARE NO DETECTABLE EVENTS PRECEDING WHATEVER CAUSES THE VEHICLE TO GO INTO "ENGINE FAILSAFE" MODE. THE VEHICLE RUNS FINE AS IT ALWAYS DOES AND THEN IT JUST HAPPENS RANDOMLY. 2. THE FAILURE, HOW OFTEN IT OCCURS, ITS CONSEQUENCES…
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2006 FORD EXPEDITION E.B. AND ENGINE FAILSAFE MODE 1. THE EVENTS LEADING UP TO THE FAILURE: THERE ARE NO DETECTABLE EVENTS PRECEDING WHATEVER CAUSES THE VEHICLE TO GO INTO "ENGINE FAILSAFE" MODE. THE VEHICLE RUNS FINE AS IT ALWAYS DOES AND THEN IT JUST HAPPENS RANDOMLY. 2. THE FAILURE, HOW OFTEN IT OCCURS, ITS CONSEQUENCES: FAILURE OCCURS AT RANDOM AND IS NOT PREDICTABLE IT JUST HAPPENS. THE VEHICLE OPERATES NORMALLY AS IT SHOULD AND IN A SPILT SECOND IT IS LIKE THE VEHICLE JUST SHUTS OFF, THE INFORMATION CENTER DISPLAYS "ENGINE IN FAILSAFE MODE". THE ENGINE IS ACTUALLY RUNNING IN FAILSAFE MODE BUT ONLY AT AN IDLE, THE POWER STEERING AND BRAKES FUNCTION HOWEVER THE THROTTLE IS TOTALLY UNRESPONSIVE IN FAILSAFE MODE, THE VEHICLE SLOWS TO A CREEP AND WILL STOP AT THE SLIGHTEST INCLINE. WHEN THE VEHICLE STOPS THE ONLY AVAILABLE OPTION IS TO TURN THE KEY OFF AND RESTART. THE VEHICLE ALWAYS RESTARTS AND RESUMES NORMAL OPERATION AND DRIVEABILTY IS FINE, JUST AS THOUGH NOTHING EVER HAPPENED. THE OCCURRENCE FIRST HAPPENED EARLY IN JANUARY 2010, AGAIN IN LATE JANUARY, THEN IN SEPTEMBER 2010 THEN AGAIN ON FEBRUARY 26 THEN TWICE TODAY FEBRUARY 28 ABOUT 20 MINUTES APART. THE CONSEQUENCES: SCARY, DANGEROUS, HAZARDOUS. FEELS LIKE AN INSURANCE CLAIM AND/OR A LAWSUIT WAITING TO HAPPEN. WHEN A VEHICLE UNDER POWER JUST SHUTS OFF INSTANTLY FOR NO APPARENT REASON IT IS LOGICAL SERIOUS INJURY OR WORSE IS A REALISTIC CONSEQUENCE. 3. WHAT WAS DONE TO CORRECT THE FAILURE: SO FAR JUST A LOT OF FORD GUESSWORK. THE INTERNET HAS A SIGNIFICANT NUMBER OF CONSUMER POSTS REGARDING VARIOUS REPAIRS MADE. THE REPORTED REPAIRS RANGE FROM SENSORS, SPARK PLUGS, COILS, CATS,FILTERS, CONVERTERS AND MORE. THE COMMON THREAD IN THESE CONSUMER REPORTS IS THE PROBLEM STILL EXISTS AND OCCURS RANDOMLY AFTER REPAIR. *TR
NHTSA ODI #10384861
59,000 miles · Jan 11, 2011
Electrical System
2006 FORD EXPEDITION SHUTS OFF WHILE DRIVING. EXTREMELY DANGEROUS. CAR WILL START BACK UP WITHOUT ANY PROBLEMS BUT WILL SHUT DOWN SPORADICALLY. *TR
NHTSA ODI #10376233
76,170 miles · Jan 6, 2011
Electrical SystemFuel System, Gasoline
MY WIFE WAS DRIVING HER 2006 FORD EXPEDITION DOWN A BUSY ROAD AT A SPEED OF ABOUT 40 MPH. SHE WAS DRIVING WITH ANOTHER FRIEND AND OUR 2 CHILDREN (18 MONTHS AND 1 WEEK!) A WRENCH SYMBOL WARNING LIGHT CAME ON AND THE VEHICLE SHUT DOWN. SHE PUT ON HER HAZARDS AND WAS ABLE TO SAFELY COME TO A STOP. SHE TURNED THE IGNITION KEY TO THE…
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MY WIFE WAS DRIVING HER 2006 FORD EXPEDITION DOWN A BUSY ROAD AT A SPEED OF ABOUT 40 MPH. SHE WAS DRIVING WITH ANOTHER FRIEND AND OUR 2 CHILDREN (18 MONTHS AND 1 WEEK!) A WRENCH SYMBOL WARNING LIGHT CAME ON AND THE VEHICLE SHUT DOWN. SHE PUT ON HER HAZARDS AND WAS ABLE TO SAFELY COME TO A STOP. SHE TURNED THE IGNITION KEY TO THE OFF POSITION AND THEN WAS ABLE TO START THE ENGINE AGAIN. AFTER TALKING TO A MECHANIC AND DOING INTERNET RESEARCH I FOUND THIS IS A VERY COMMON PROBLEM WHICH CONSISTS OF THE ELECTRONIC CONTROL OF THE THROTTLE. THE FIX IS UPWARDS OF $500; SO A RECALL OF SOMETHING THAT EXPENSIVE CAN EASILY BE BRUSHED UNDER THE TABLE BY FORD. THIS PROBLEM NEEDS TO BE ADDRESSED BY FORD. IF MORE VEHICLES KEEP SHUTTING DOWN ON THEIR OWN SOMEONE WILL SOON BE INJURED OR KILLED. *TR
NHTSA ODI #10374970
66,816 miles · Sep 9, 2010
Electrical System
I WAS DRIVING 45 MILES AN HOUR DOWN A MAJOR HIGHWAY WHEN MY ENGINE IN MY 2006 FOR EXPEDITION JUST SHUT DOWN WITHOUT WARNING AND WENT INTO "FAIL -SAFE MODE". THANK GOD I WAS ABLE TO CROSS 3 LANES OF TRAFFIC WITHOUT INCIDENT TO GET TO THE SHOULDER. I SHUT OFF MY CAR AS THE MANUAL TOLD ME TOO. AFTER 20 MINS I WAS ABLE TO RESTART TH…
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I WAS DRIVING 45 MILES AN HOUR DOWN A MAJOR HIGHWAY WHEN MY ENGINE IN MY 2006 FOR EXPEDITION JUST SHUT DOWN WITHOUT WARNING AND WENT INTO "FAIL -SAFE MODE". THANK GOD I WAS ABLE TO CROSS 3 LANES OF TRAFFIC WITHOUT INCIDENT TO GET TO THE SHOULDER. I SHUT OFF MY CAR AS THE MANUAL TOLD ME TOO. AFTER 20 MINS I WAS ABLE TO RESTART THE CAR. I DROVE TO THE NEAREST DEALERSHIP SO THEY COULD LOOK INTO THE ISSUE. IT WAS DIAGNOSED AS NEEDING A REPLACEMENT THROTTLE BODY. WHEN I ASKED "WHAT HAPPENED? WHY DID THIS HAPPEN?", I WAS TOLD "IT JUST HAPPENS," AND "THERE IS NOTHING PREVENTATIVE THAT CAN BE DONE.". CONVENIENTLY THIS PART WAS NOT COVERED BY MY 100,000 MILE POWERTRAIN WARRANTY THAT FORD IS SO PROUD OF ON ITS USED VEHICLES. THIS REPAIR COST ME $609. THE NEXT DAY I DID SOME RESEARCH AND FOUND NUMEROUS COMPLAINTS ON THE EXACT SAME ISSUE FOR THE SAME MAKE AND MODEL (2006 FORD EXPEDITION) ON THE FOLLOWING WEBSITE: HTTP://WWW.ABOUTAUTOMOBILE.COM/COMPLAINT/2006/FORD/EXPEDITION/ENGINE+AND+ENGINE+COOLING+SYSTEM . I CALLED THE SERVICE MANAGER TO DISCUSS AND HE AGREED HE HAS BEEN SEEING ALOT OF THESE THROTTLE BODY REPLACEMENTS AND ENGINE SHUTDOWNS ON THIS MODEL AND AGREES A RECALL NEEDS TO BE DONE BEFORE SOMEONE GETS SERIOUSLY HURT. I AM JUST THANKFUL MY 3 KIDS WERE NOT IN THE CAR WITH ME AND PRAY THIS DOESN'T HAPPEN AGAIN. THE SERVICE MANAGER GAVE ME THIS WEB ADDRESS TO MAKE AN OFFICIAL COMPLAINT, HOPING A RECALL WOULD TAKE PLACE. *TR
NHTSA ODI #10354633
41,480 miles · Jun 24, 2010
Electrical SystemEngine And Engine Cooling
MY WIFE, THREE KIDS AND MYSELF WERE IN OUR 2006 FORD EXPEDITION LIMITED COMING DOWN A MOUNTAIN PASS IN LAKE TAHOE WHEN ALL OF A SUDDEN THE ENGINE STOPPED! A CODE ON THE DASH READ "FAIL SAFE ENGINE MODE". THE STEERING WHEEL LOCKED AND THERE WAS NO POWER, NO ACCELERATION. I WAS LUCKY TO PULL TO THE SIDE OF THE ROAD. THE FOLLOW…
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MY WIFE, THREE KIDS AND MYSELF WERE IN OUR 2006 FORD EXPEDITION LIMITED COMING DOWN A MOUNTAIN PASS IN LAKE TAHOE WHEN ALL OF A SUDDEN THE ENGINE STOPPED! A CODE ON THE DASH READ "FAIL SAFE ENGINE MODE". THE STEERING WHEEL LOCKED AND THERE WAS NO POWER, NO ACCELERATION. I WAS LUCKY TO PULL TO THE SIDE OF THE ROAD. THE FOLLOWING DAY, I TOOK THE TRUCK TO THE CARSON CITY, NV FORD DEALER AND PAID FOR A DIAGNOSTIC. NOTES FROM DEALER: ROAD TEST COULD NOT VERIFY. PERFORMED EEC SELF TEST, HAS CODE P0104. PERFORMED WIGGLE TEST AND PINPOINT TESTS. PERFORMED RECORDER-MONITOR TEST ALL THE PIDS LOOKED GOOD. REMOVED THE MAF SENSOR. HAS DEBRIS ON THE MAF SENSOR WIRES. RECOMMEND A NEW MAF SENSOR." I PUT IN A NEW MAF SENSOR AND AIR FILTER. IN DRIVING LESS THAN 3 MILES AFTER THIS WAS DONE, THE TRUCK DID THE SAME THING. THE "FAIL SAFE ENGINE MODE" CAME ON, LOSS OF POWER AND ACCELERATION. I HAD TO TURN THE TRUCK OFF COMPLETELY, REMOVE KEY AND RESTART. THEN THE TRUCK DID NOT HOLD THE IDLE AND DIED. AFTER A SECOND TIME, THE TRUCK RESTARTED. I AM STILL DRIVING WITH THE CHECK ENGINE LIGHT OFF AND HAVE ANOTHER APPOINTMENT WITH THE FORD DEALER TOMORROW MORNING (6-24-10) TO SEE WHAT IS GOING ON. WE ARE SUPPOSED TO LEAVE TOMORROW AND DRIVE 1100 MILES TO RETURN TO DENVER. *TR
NHTSA ODI #10339814
60,000 miles · Mar 14, 2010
Electrical SystemEngine And Engine Cooling
SPARKS PLUGS BLEW OUT RIGHT AT 60,000 MILES ON 2006 FORD EXPEDITION ON OUR WAY FROM MARYLAND TO LOUISIANA. STARTED GETTING PROBLEMS IN NORTH CAROLINA. AFTER SPENDING 2000.00 FOR HOTEL, RENTAL CAR AND POSSIBLE FIX BY FIRESTONE..IT STILL WAS NOT WORKING. BROUGHT TO FORD DEALERSHIP AND SAID IT WAS SPARK PLUGS THAT BLEW AND A COM…
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SPARKS PLUGS BLEW OUT RIGHT AT 60,000 MILES ON 2006 FORD EXPEDITION ON OUR WAY FROM MARYLAND TO LOUISIANA. STARTED GETTING PROBLEMS IN NORTH CAROLINA. AFTER SPENDING 2000.00 FOR HOTEL, RENTAL CAR AND POSSIBLE FIX BY FIRESTONE..IT STILL WAS NOT WORKING. BROUGHT TO FORD DEALERSHIP AND SAID IT WAS SPARK PLUGS THAT BLEW AND A COMMON THING FOR F150S AND IT WOULD COST OVER 7,000.00 TO FIX IT AND RECOMMENDED TRADING IT IN. SO WE DID CAUSE WE HAD NO CHOICE WITH THE TRUCK BEING IN NC. *TR
NHTSA ODI #10319602
78,123 miles · Feb 18, 2010
Electrical SystemFuel System, Gasoline
ENGINE SHUTS OFF WHILE RUNNING. LAST TIME ON THE FREEWAY. MY MECHANIC SAYS THE SYSTEMS READS OK ON COMPUTER DIAGNOSTIC, BUT THE FAIL-SAFE SYSTEM DEFINITELY SHUT THE ENGINE DOWN DUE TO A POSSIBLE GLITCH IN THE SYSTEM. DEALERS "SEE" GOOD READINGS FOR THROTTLE SYSTEM AND WILL NOT REPLACE A "GOOD" PART. WHEN THIS HAPPENS, CAR HAS NO…
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ENGINE SHUTS OFF WHILE RUNNING. LAST TIME ON THE FREEWAY. MY MECHANIC SAYS THE SYSTEMS READS OK ON COMPUTER DIAGNOSTIC, BUT THE FAIL-SAFE SYSTEM DEFINITELY SHUT THE ENGINE DOWN DUE TO A POSSIBLE GLITCH IN THE SYSTEM. DEALERS "SEE" GOOD READINGS FOR THROTTLE SYSTEM AND WILL NOT REPLACE A "GOOD" PART. WHEN THIS HAPPENS, CAR HAS NO POWER WITH NO WARNING. IT HAS HAPPENED TWICE AND WE DON'T KNOW WHEN IT WILL HAPPEN AGAIN. *TR
NHTSA ODI #10311621
30,000 miles · Jul 14, 2008
Electrical System
TL*THE CONTACT OWNS A 2006 FORD EXPEDITION. WHILE DRIVING APPROXIMATELY 70 MPH, THE VEHICLE COMPLETELY SHUT OFF WITHOUT WARNING. THE VEHICLE HAD TO BE MANEUVERED ACROSS FOUR LANES OF TRAFFIC, BUT WAS RESTARTED ON THE FIRST ATTEMPT. THE CURRENT AND FAILURE MILEAGES WERE 30,000. UPDATED 09/10/08. *LJ UPDATED 09/11/08.*JB
NHTSA ODI #10234170
17,000 miles · Oct 30, 2006
Electrical SystemFire
VEHICLE HAD BEEN DISPLAYING THE LOW AIR PRESSURE LIGHT AND THE CHECK ENGINE LIGHT ( SMOG CONTROL). TIRES WERE CHECKED AND FOUND TO BE PROPERLY INFLATED, ALL FLUIDS, FILTERS, ETC, WERE CHECKED AND FOUND TO BE IN WORKING ORDER. VEHICLE WAS DRIVEN APPROXIMATELY 15-20 MILES. BOTH BEFORE MENTION LIGHTS CONTINUED TO COME ON AND OFF. V…
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VEHICLE HAD BEEN DISPLAYING THE LOW AIR PRESSURE LIGHT AND THE CHECK ENGINE LIGHT ( SMOG CONTROL). TIRES WERE CHECKED AND FOUND TO BE PROPERLY INFLATED, ALL FLUIDS, FILTERS, ETC, WERE CHECKED AND FOUND TO BE IN WORKING ORDER. VEHICLE WAS DRIVEN APPROXIMATELY 15-20 MILES. BOTH BEFORE MENTION LIGHTS CONTINUED TO COME ON AND OFF. VEHICLE WAS PARKED. APPROX 1 HOUR LATER VEHICLE HORN SOUNDED, I WALKED TO CHECK HORN AND FOUND THE VEHICLE INTERIOR IN FLAMES. I WAS ABLE TO PUT THE FIRE OUT, AND KEEP THE DAMAGE TO THE DRIVERS SIDE DASH, STEERING AREA. VEHICLE INTERIOR SUFFERED HEAVY SMOKE DAMAGE, FRONT WINDSHIELD CRACKED. CONTACTED INSURANCE COMPANY AND FORD MOTOR COMPANY. VEHICLE IS ONLY 9 MONTHS OLD AND STILL UNDER WARRANTY. I REQUESTED THAT FORD REPLACE MY VEHICLE WITH ANOTHER VEHICLE JUST LIKE I PURCHASED. FORD SENT LETTER SAYING THAT SINCE INSURANCE COMPANY IS INVOLVED THEY PROPOSE NO FURTHER ACTION. BUT SINCE VEHICLE IS USED, INSURANCE COMPANY WILL ONLY PAY FAIR MARKET VALUE, LEAVING ME TO PAY FOR THE BALANCE. ALL I WANT IS FOR FORD TO REPLACE MY DEFECTIVE VEHICLE. *JB
NHTSA ODI #10172196
Mileage unknown · Aug 11, 2006
Electrical SystemInjury
I BOUGHT A 2006 FORD EXPEDITION AND 3 MONTHS LATER WHILE MY DAD WAS DRIVING IT ACCELERATED BY IT SELF AND MY DAD DIE IN THE ACCIDENT CAUSED BY UNEXPECTED ACCELERATION OF THE VEHICLE. *NM
NHTSA ODI #10165260
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