NHTSA owner reports · September 18, 2026 snapshot.
Engine complaints
87 reportsClear category filter110,000 miles · Dec 28, 2015
Engine
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING AT VARIOUS SPEEDS, THE FAIL SAFE WARNING INDICATOR ILLUMINATED AS THE ENGINE STALLED. THE CONTACT STATED THAT THE VEHICLE HAD TO BE SHIFTED INTO THE PARK POSITION IN ORDER TO BE RESTARTED. THE FAILURE RECURRED NUMEROUS TIMES. THE VEHICLE WAS NOT T…
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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING AT VARIOUS SPEEDS, THE FAIL SAFE WARNING INDICATOR ILLUMINATED AS THE ENGINE STALLED. THE CONTACT STATED THAT THE VEHICLE HAD TO BE SHIFTED INTO THE PARK POSITION IN ORDER TO BE RESTARTED. THE FAILURE RECURRED NUMEROUS TIMES. THE VEHICLE WAS NOT TAKEN TO A DEALER TO BE DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS APPROXIMATELY 110,000.
NHTSA ODI #10816393
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…
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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
95,962 miles · Nov 5, 2015
Engine
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. WHILE DRIVING 35 MPH, THE VEHICLE SUDDENLY LOST POWER AND THE "ENGINE FAIL SAFE MODE" WARNINIG ILLUMINATED ON THE INSTRUMENT PANEL. THE CONTACT COASTED TO THE SIDE OF THE ROAD AND SHUT OFF THE ENGINE. THE VEHICLE WAS RESTARTED AFTER A FEW MINUTES, BUT THE WARNING INDICATOR RECURRED. T…
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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. WHILE DRIVING 35 MPH, THE VEHICLE SUDDENLY LOST POWER AND THE "ENGINE FAIL SAFE MODE" WARNINIG ILLUMINATED ON THE INSTRUMENT PANEL. THE CONTACT COASTED TO THE SIDE OF THE ROAD AND SHUT OFF THE ENGINE. THE VEHICLE WAS RESTARTED AFTER A FEW MINUTES, BUT THE WARNING INDICATOR RECURRED. THE CONTACT CALLED A LOCAL DEALER WHO WAS UNABLE TO EXPLAIN THE FAILURE, BUT ASKED TO SEE THE VEHICLE FOR DIAGNOSTIC TESTING. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 95,962.
NHTSA ODI #10788701
190,000 miles · Oct 29, 2015
Engine
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. WHILE DRIVING AT APPROXIMATELY 35 MPH, THE "ENGINE SAFE FAIL MODE" WARNING MESSAGE ILLUMINATED. THE VEHICLE WAS TAKEN TO A DEALER WHO WAS UNABLE TO DETERMINE THE FAILURE. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE APPROXIMATE FAILURE MILEAGE W…
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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. WHILE DRIVING AT APPROXIMATELY 35 MPH, THE "ENGINE SAFE FAIL MODE" WARNING MESSAGE ILLUMINATED. THE VEHICLE WAS TAKEN TO A DEALER WHO WAS UNABLE TO DETERMINE THE FAILURE. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE APPROXIMATE FAILURE MILEAGE WAS 190,000.
NHTSA ODI #10787029
120,000 miles · Oct 28, 2015
Engine
I HAVE HAD TWO SITUATIONS WHERE MY SUV ENGINE EXPECTEDLY SHUTS OFF. 1.) WHILE DRIVING IN STOP AND GO TRAFFIC 2.) TURNING INTO A PARKING LOT AFTER PUTTING THE SUV IN PARK, I CAN IMMEDIATE TURN BACK ON.
NHTSA ODI #10786860
141,000 miles · Oct 23, 2015
EnginePower Train
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. WHILE DRIVING 45 MPH, THE VEHICLE LOST POWER. WHEN THE ACCELERATOR PEDAL WAS DEPRESSED, THE VEHICLE FAILED TO ACCELERATE AND THE RPMS INCREASED. THE CHECK ENGINE AND SERVICE VEHICLE SOON WARNING LIGHTS ILLUMINATED. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE FAILURE RECURRED ON NUM…
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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. WHILE DRIVING 45 MPH, THE VEHICLE LOST POWER. WHEN THE ACCELERATOR PEDAL WAS DEPRESSED, THE VEHICLE FAILED TO ACCELERATE AND THE RPMS INCREASED. THE CHECK ENGINE AND SERVICE VEHICLE SOON WARNING LIGHTS ILLUMINATED. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE FAILURE RECURRED ON NUMEROUS OCCASIONS. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 141,000.
NHTSA ODI #10785496
75,000 miles · Oct 8, 2015
Engine
WE WERE EXPERIENCING STALLS AND OVERALL SLUGGISHNESS AND TOOK IT TO A MECHANIC WHO TOLD US WE NEEDED A TUNE UP. MY HUSBAND USUALLY DOES MINOR UPKEEP, THANKED THE MAN AND WAS ABOUT TO TAKE OUR TRUCK HOME WHEN THE MECHANIC INFORMED US THAT THE PLUGS WERE A BEAR TO CHANGE SINCE WE WOULD NEED A SPECIAL TOOL AND CHANCES ARE, THE PLU…
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WE WERE EXPERIENCING STALLS AND OVERALL SLUGGISHNESS AND TOOK IT TO A MECHANIC WHO TOLD US WE NEEDED A TUNE UP. MY HUSBAND USUALLY DOES MINOR UPKEEP, THANKED THE MAN AND WAS ABOUT TO TAKE OUR TRUCK HOME WHEN THE MECHANIC INFORMED US THAT THE PLUGS WERE A BEAR TO CHANGE SINCE WE WOULD NEED A SPECIAL TOOL AND CHANCES ARE, THE PLUGS WOULD BREAK OFF. WE WERE SKEPTICAL BUT TRUSTED HIM TO DO THE JOB. IT COST SO MUCH AND TOOK SO LONG, WE BOUGHT A BEATER CAR IN THE INTERIM SO WE COULD GET TO WORK! AND IT COST OVER $1000...FOR A TUNE UP!!! IT LOOKS LIKE FORD KNOWS FULL WELL ABOUT THIS BUILT IN MONEY MAKER SINCE I SEE WE ARE IN GOOD COMPANY WITH MANY OWNERS COMPLAINING ABOUT THE EXACT SAME ISSUE. SHAME ON FORD.
NHTSA ODI #10780878
111,000 miles · Jul 31, 2015
Engine
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. WHILE PARKED, THE VEHICLE STALLED SHORTLY AFTER BEING STARTED. THE CONTACT WAS ABLE TO RESTART THE VEHICLE, BUT THE ENGINE WARNING INDICATOR ILLUMINATED. THIS WAS A RECURRING FAILURE. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE APPR…
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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. WHILE PARKED, THE VEHICLE STALLED SHORTLY AFTER BEING STARTED. THE CONTACT WAS ABLE TO RESTART THE VEHICLE, BUT THE ENGINE WARNING INDICATOR ILLUMINATED. THIS WAS A RECURRING FAILURE. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 111,000.
NHTSA ODI #10745352
194,549 miles · Jul 9, 2015
Engine
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. WHILE DRIVING 60 MPH, THE VEHICLE MADE A RATTLING NOISE. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHERE IT WAS DIAGNOSED THAT THE VEHICLE'S ENGINE NEEDED TO BE REPAIRED OR REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEA…
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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. WHILE DRIVING 60 MPH, THE VEHICLE MADE A RATTLING NOISE. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHERE IT WAS DIAGNOSED THAT THE VEHICLE'S ENGINE NEEDED TO BE REPAIRED OR REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 194,549.
NHTSA ODI #10733064
164,500 miles · Jul 1, 2015
Engine
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. WHILE DRIVING 65 MPH, THE ENGINE WARNING LIGHT ILLUMINATED AND FLICKERED WHEN ACCELERATING. THE FAILURE RECURRED INTERMITTENTLY. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 164,500.
NHTSA ODI #10731606
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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