NHTSA owner reports · September 18, 2026 snapshot.
Engine complaints
87 reportsClear category filter195,000 miles · Jan 13, 2017
Engine
ENGINE FAIL SAFE MODE ENGAGES AT VARIOUS AND UNPREDICTABLE SPEEDS AND AT ANY GIVEN TIME. IT HAS HAPPENED NUMEROUS TIMES AND SHOWS NO CODE AFTERWARDS. A VERY DANGEROUS ISSUE THAT NEEDS TO BE ADDRESSED BY FORD. I HAVE FOUND THOUSANDS OF COMPLAINTS ABOUT THIS ISSUE BUT I CAN FIND NO INDICATION THAT FORD HAS BEEN WILLING TO ADDRESS…
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ENGINE FAIL SAFE MODE ENGAGES AT VARIOUS AND UNPREDICTABLE SPEEDS AND AT ANY GIVEN TIME. IT HAS HAPPENED NUMEROUS TIMES AND SHOWS NO CODE AFTERWARDS. A VERY DANGEROUS ISSUE THAT NEEDS TO BE ADDRESSED BY FORD. I HAVE FOUND THOUSANDS OF COMPLAINTS ABOUT THIS ISSUE BUT I CAN FIND NO INDICATION THAT FORD HAS BEEN WILLING TO ADDRESS THE ISSUE. WHEN ASKED FOR THE DATE THE INCIDENT HAPPENED I AM ENTERING THE DATE OF COMPLAINT BECAUSE THIS HAS HAPPENED MULTIPLE TIMES. NO CODES DOES NOT MEAN THE VEHICLE DOESN'T HAVE ISSUES. FORD NEEDS TO ADDRESS THIS ISSUE....RECALL AND CORRECT THE PROBLEM.
NHTSA ODI #10944979
80,000 miles · Nov 7, 2016
Engine
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. WHILE DRIVING AT VARIOUS SPEEDS AND AFTER A LOUD ALARM SOUND, THE VEHICLE STALLED AND THE ENGINE WARNING LIGHT ILLUMINATED. THE VEHICLE WAS TAKEN TO THE DEALER WHERE THE SPARK PLUGS WERE REPLACED AND THE MECHANIC INFORMED THE CONTACT THAT THE CATALYTIC CONVERTER WAS FAILING. THE FAILU…
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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. WHILE DRIVING AT VARIOUS SPEEDS AND AFTER A LOUD ALARM SOUND, THE VEHICLE STALLED AND THE ENGINE WARNING LIGHT ILLUMINATED. THE VEHICLE WAS TAKEN TO THE DEALER WHERE THE SPARK PLUGS WERE REPLACED AND THE MECHANIC INFORMED THE CONTACT THAT THE CATALYTIC CONVERTER WAS FAILING. THE FAILURE HAD REOCCURRED ON SEVERAL OCCASIONS. THE FAILURE MILEAGE WAS 80,000.
NHTSA ODI #10924646
135,000 miles · Oct 25, 2016
Engine
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. WHILE DRIVING OVER 50 MPH, THE VEHICLE SHOOK VIGOROUSLY AND THE CHECK ENGINE WARNING INDICATOR ILLUMINATED. THE VEHICLE WAS TAKEN TO A DEALER, BUT WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 135,000.
NHTSA ODI #10918834
Mileage unknown · Oct 17, 2016
Engine
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT THE ENGINE FAIL SAFE MODE WARNING INDICATOR RANDOMLY FLASHED. THE VEHICLE'S SPEED REDUCED AND STALLED SEVERAL TIMES. THE VEHICLE WAS TAKEN TO A MANUFACTURER'S MASTER MECHANIC FOR FURTHER DIAGNOSTIC TESTING. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT…
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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT THE ENGINE FAIL SAFE MODE WARNING INDICATOR RANDOMLY FLASHED. THE VEHICLE'S SPEED REDUCED AND STALLED SEVERAL TIMES. THE VEHICLE WAS TAKEN TO A MANUFACTURER'S MASTER MECHANIC FOR FURTHER DIAGNOSTIC TESTING. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED. THE FAILURE MILEAGE WAS NOT AVAILABLE.
NHTSA ODI #10916527
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…
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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
86,900 miles · Jun 6, 2016
EnginePower TrainSteering
MY 2006 FORD EXPEDITION'S "ENGINE FAILSAFE MODE" INITIATED AND ALERTED ME WHILE I WAS OPERATING THE VEHICLE, WHICH RESULTED IN THE VEHICLE SHUTTING DOWN COMPLETELY AND LOSING ALL POWER. MY MAIN ISSUE/CONCERN WITH THIS IS THAT I LOST STEERING AND A SIGNIFICANT AMOUNT OF BRAKING POWER. FORTUNATELY, I WAS ON A SIDE ROAD AND WAS ABL…
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MY 2006 FORD EXPEDITION'S "ENGINE FAILSAFE MODE" INITIATED AND ALERTED ME WHILE I WAS OPERATING THE VEHICLE, WHICH RESULTED IN THE VEHICLE SHUTTING DOWN COMPLETELY AND LOSING ALL POWER. MY MAIN ISSUE/CONCERN WITH THIS IS THAT I LOST STEERING AND A SIGNIFICANT AMOUNT OF BRAKING POWER. FORTUNATELY, I WAS ON A SIDE ROAD AND WAS ABLE TO SAFELY PULL OVER OUT OF HARM'S WAY. THE VEHICLE WAS ABLE TO START A COUPLE OF TRIES LATER, AND I WAS ABLE TO GET THE VEHICLE INTO A SERVICE SHOP SAFELY, WHICH WAS OVER AN HOUR AWAY. I CANNOT HELP BUT BE GRATEFUL FOR GETTING HOME SAFELY, BUT AM VERY CONCERNED ABOUT THESE VEHICLES EXPERIENCING SUCH ISSUES AS THEY TRAVERSE MAJOR THOROUGHFARES, ESPECIALLY ON A HIGHWAY TRAVELING AROUND 70MPH. THIS POTENTIALLY POSED VERY IMPACTFUL CONSEQUENCES AND PUTS MYSELF, FRIENDS/FAMILY TRAVELING WITH ME, AND OTHER MOTORISTS.
NHTSA ODI #10872668
120,000 miles · Jun 2, 2016
Engine
WHILE DRIVING ON A HIGHWAY AT 60 MPH AND ON A CITY STREET AT 40 MPH THE VEHICLE WITHOUT ANY WARNING SHUTS OFF AND GOES INTO ENGINE FAIL SAFE MODE, THE VEHICLE STILL HAS BRAKING AND STEERING AND AFTER TURNING IGNITION KEY TO OFF THEN ON IT RESTARTS AND DRIVES FINE. THIS VEHICLE HAS 120,000 MILES ON IT .
NHTSA ODI #10872106
158,307 miles · Mar 9, 2016
Engine
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. WHILE DRIVING 50 MPH, THE ENGINE LIGHT ILLUMINATED, THE VEHICLE LOST POWER, JERKED, AND STALLED. THE CONTACT HAD TO RESTART THE VEHICLE TO RESUME NORMAL OPERATION. IN ADDITION, WHILE DRIVING AT 50 MPH, THE VEHICLE REPEATEDLY SLOW DOWN AND ACCELERATE. THE FAILURE RECURRED A FEW TIMES. …
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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. WHILE DRIVING 50 MPH, THE ENGINE LIGHT ILLUMINATED, THE VEHICLE LOST POWER, JERKED, AND STALLED. THE CONTACT HAD TO RESTART THE VEHICLE TO RESUME NORMAL OPERATION. IN ADDITION, WHILE DRIVING AT 50 MPH, THE VEHICLE REPEATEDLY SLOW DOWN AND ACCELERATE. THE FAILURE RECURRED A FEW TIMES. THE VEHICLE WAS TAKEN TO THE DEALER WHERE IT WAS DIAGNOSED THAT THE SPARK PLUGS NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 158,307.
NHTSA ODI #10845751
115,000 miles · Jan 12, 2016
Engine
WHILE TAKING MY KIDS TO DAYCARE THE ENGINE FAIL SAFE LIGHT CAME ON AND THE ENGINE SHUT DOWN. I WAS SITTING AT A LIGHT WAITING TO GO STRAIGHT UNDER A BRIDGE AND AT THIS PARTICULAR LIGHT ONLY ONE LANE CAN GO STRAIGHT SINCE THE ENGINE SHUT DOWN AND I COULD NOT MOVE THIS CAUSED MAJOR BACKUP. LUCKILY THERE WAS AN EMERGENCY VEHICLE A…
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WHILE TAKING MY KIDS TO DAYCARE THE ENGINE FAIL SAFE LIGHT CAME ON AND THE ENGINE SHUT DOWN. I WAS SITTING AT A LIGHT WAITING TO GO STRAIGHT UNDER A BRIDGE AND AT THIS PARTICULAR LIGHT ONLY ONE LANE CAN GO STRAIGHT SINCE THE ENGINE SHUT DOWN AND I COULD NOT MOVE THIS CAUSED MAJOR BACKUP. LUCKILY THERE WAS AN EMERGENCY VEHICLE A FEW CARS BEHIND AND HE WAS ABLE TO PUSH ME THROUGH THE LIGHT AND INTO A PARKING LOT. AFTER A FEW MINUTES OF SITTING THERE THE TRUCK STARTED AND I WAS ABLE TO GET THEM TO DAYCARE AND CONTINUE ON TO WORK. VERY DANGEROUS SITUATION AND SOMETHING SHOULD BE DONE.
NHTSA ODI #10819673
146,000 miles · Jan 11, 2016
Engine
MY VEHICLE HAS COMPLETELY SHUT DOWN IN THE MIDDLE OF DRIVING ON SEVERAL OCCASIONS. I HAVE HAD DIAGNOSTIC REPORTS RUN AND THEY DO NOT FIND ANY PROBLEMS. THE FIRST TIME I WAS GOING 45 MPH AND WAS ABLE TO COAST INTO A SONIC. I WAITED ABOUT 15 MINUTES AND THE CAR STARTED BACK UP. THE SECOND TIME WAS AT A GAS STATION AND MY CAR W…
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MY VEHICLE HAS COMPLETELY SHUT DOWN IN THE MIDDLE OF DRIVING ON SEVERAL OCCASIONS. I HAVE HAD DIAGNOSTIC REPORTS RUN AND THEY DO NOT FIND ANY PROBLEMS. THE FIRST TIME I WAS GOING 45 MPH AND WAS ABLE TO COAST INTO A SONIC. I WAITED ABOUT 15 MINUTES AND THE CAR STARTED BACK UP. THE SECOND TIME WAS AT A GAS STATION AND MY CAR WOULD NOT START. I HAD A DIAGNOSTIC RUN AND WAS TOLD IT WAS MY BATTERY. I REPLACED THE BATTERY AND MY VEHICLE DIED AGAIN THE NEXT DAY, BUT STARTED BACK UP ONE I LET IT SIT FOR A FEW MINUTES. THIS MORNING I WAS PULLING INTO A PARKING LOT AT WORK AND IT DIED. AFTER ABOUT 10 MINUTES IT STARTED BACK UP AND I WAS ABLE TO PULL INTO A PARKING SPOT. I WENT TO LEAVE FOR LUNCH AND NOW MY VEHICLE WILL NOT START AT ALL. THIS COULD HAVE BEEN MUCH WORSE IF I WERE DRIVING DOWN THE INTERSTATE AND THE CAR SHUT OFF ON ME LIKE IT HAS DONE OTHER TIMES. I HAVE TWO CHILDREN AND THE THOUGHT OF THEM IN THIS CAR DOES NOT MAKE ME FEEL SAFE!!
NHTSA ODI #10819422
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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