TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT THE ELECTRONIC THROTTLE CONTROL AND THE SERVICE ENGINE WARNING INDICATORS ILLUMINATED. THE VEHICLE STALLED, BUT WAS ABLE TO BE RESTARTED AND RESUME NORMAL OPERATION. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. …
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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT THE ELECTRONIC THROTTLE CONTROL AND THE SERVICE ENGINE WARNING INDICATORS ILLUMINATED. THE VEHICLE STALLED, BUT WAS ABLE TO BE RESTARTED AND RESUME NORMAL OPERATION. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 120,000.
NHTSA ODI #10638800
135,000 miles · Sep 10, 2014
Electrical SystemEngine
ENGINE JUST SHUTS OFF, ESPECIALLY AT A STAND STILL & A/C ON. NOT AS OFTEN IF A/C IS NOT ON. *TR
NHTSA ODI #10632045
90,000 miles · Aug 7, 2014
EngineFuel/propulsion System
ENGINE WENT IN TO FAIL SAFE MODE AND STALLED WHILE COASTING TO PULL OFF. PUT IN NEUTRAL SHUT OFF KEY AND THEN RESTARTED. NO MORE PROBLEM..UNTIL A YEAR LATER. FAIL SAFE THEN STALL. RESTARTED AND CHECK ENGINE LIGHT ON. AFTER 10 MILES FAIL SAFE AND STALL. RESTARTED CHECK ENGINE LIGHT ON TOOK TO DEALER. DIAGNOSED AS THROTTLE BODY $6…
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ENGINE WENT IN TO FAIL SAFE MODE AND STALLED WHILE COASTING TO PULL OFF. PUT IN NEUTRAL SHUT OFF KEY AND THEN RESTARTED. NO MORE PROBLEM..UNTIL A YEAR LATER. FAIL SAFE THEN STALL. RESTARTED AND CHECK ENGINE LIGHT ON. AFTER 10 MILES FAIL SAFE AND STALL. RESTARTED CHECK ENGINE LIGHT ON TOOK TO DEALER. DIAGNOSED AS THROTTLE BODY $650 REPAIR. OBVIOUSLY; I AM NOT THE FIRST VICTIM! SHAME ON YOU FORD FOR NOT STEPPING UP AND TAKING CARE OF YOUR CUSTOMERS AND REPLACING THE THROTTLE BODIES. TO CONSUMERS..FAIL SAFE DOESN'T MEAN SAFE TO KEEP DRIVING, IT IS DESIGNED TO KEEP THE ENGINE RUNNING JUST LONG ENOUGH TO MAINTAIN POWER STEERING AND BRAKES WHILE YOU PULL OVER. GOOD LUCK! *TR
NHTSA ODI #10620711
115,000 miles · Jul 29, 2014
Electronic Stability Control (esc)EngineVehicle Speed Control
THE CAR STALLED WHILE TURNING NO WARNING AT 25MPH START AND SHUT DOES IT 6 TIMES GOING HOME. *JS
NHTSA ODI #10617085
68,685 miles · Jul 4, 2014
EngineSteering
DRIVING IN TOWN ON FOUR LANE AT 45 MPH. FAIL SAFE LIGHT APPEARED AND ENGINE CUT OFF AND LOST POWER STEERING. ALMOST REAR ENDED AS THERE WAS NO PLACE TO PULL OFF THE ROAD! ENGINE WAS RESTARTED AND DID NOT OCCUR AGAIN WHILE RETURNING HOME. *TR
NHTSA ODI #10608197
123,000 miles · May 27, 2014
Engine
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED WHILE DRIVING APPROXIMATELY 60 MPH, THE VEHICLE STALLED AND THE ENTIRE INSTRUMENT PANEL ILLUMINATED. THIS FAILURE OCCURRED SIX TIMES OVER A PERIOD OF SIX MONTHS. THE VEHICLE WAS TAKEN TO A DEALER WHO WAS UNABLE TO DUPLICATE THE FAILURE. THE MANUFACTURER WAS NOT…
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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED WHILE DRIVING APPROXIMATELY 60 MPH, THE VEHICLE STALLED AND THE ENTIRE INSTRUMENT PANEL ILLUMINATED. THIS FAILURE OCCURRED SIX TIMES OVER A PERIOD OF SIX MONTHS. THE VEHICLE WAS TAKEN TO A DEALER WHO WAS UNABLE TO DUPLICATE THE FAILURE. THE MANUFACTURER WAS NOT NOTIFIED OF THE DEFECT. THE APPROXIMATE FAILURE MILEAGE WAS 123,000.
NHTSA ODI #10594383
97,000 miles · May 16, 2014
Engine
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT WHILE ATTEMPTING TO MERGE INTO TRAFFIC, THE VEHICLE HESITATED TO ACCELERATE AND MISFIRED WITHOUT ANY WARNING. THE VEHICLE WAS TAKEN TO THE DEALER. THE TECHNICIAN DIAGNOSED THAT THE SPARK PLUGS NEEDED TO BE REPLACED. THE MANUFACTURER WAS MADE AWARE OF THE FAILUR…
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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT WHILE ATTEMPTING TO MERGE INTO TRAFFIC, THE VEHICLE HESITATED TO ACCELERATE AND MISFIRED WITHOUT ANY WARNING. THE VEHICLE WAS TAKEN TO THE DEALER. THE TECHNICIAN DIAGNOSED THAT THE SPARK PLUGS NEEDED TO BE REPLACED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 97,000 AND THE CURRENT MILEAGE WAS 98,500.
NHTSA ODI #10588814
120,549 miles · Apr 25, 2014
Engine
2006 EXPEDITION FAIL SAFE MODE CAME ON WHILE DRIVING MY CHILDREN TO SCHOOL. CAR IMMEDIATELY SLOWED TO UNDER 10MPH. WAS BARELY ABLE TO PULL OVER AND RESTART IT. THANK GOODNESS I WAS NOT ON THE EXPRESSWAY DOING 60+ MPH. THERE ARE NUMEROUS COMPLAINTS ON THIS ISSUE WITH THIS CAR. IT WAS VERY SCARY! *TR
NHTSA ODI #10584816
116,000 miles · Apr 23, 2014
EngineFuel System, GasolinePower Train
WAS DRIVING DOWN OFF RAMP LOST ALL POWER TO THE VEHICLE, NO STEERING, NO BRAKES. I HAD MY 3 CHILDREN IN THE VEHICLE WITH ME AND THANKFULLY I WAS ABLE TO COST TO THE SHOULDER UNTIL HELP ARRIVED. EXTREMELY SCARY HAD IT HAPPEN 2 MINUTES EARLIER WOULD OF BEEN OFF THE RAMP AND INTO ONCOMING TRAFFIC! THIS IS UNACCEPTABLE!! MY MECHANIC…
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WAS DRIVING DOWN OFF RAMP LOST ALL POWER TO THE VEHICLE, NO STEERING, NO BRAKES. I HAD MY 3 CHILDREN IN THE VEHICLE WITH ME AND THANKFULLY I WAS ABLE TO COST TO THE SHOULDER UNTIL HELP ARRIVED. EXTREMELY SCARY HAD IT HAPPEN 2 MINUTES EARLIER WOULD OF BEEN OFF THE RAMP AND INTO ONCOMING TRAFFIC! THIS IS UNACCEPTABLE!! MY MECHANIC SAYS IT'S THE FUEL PUMP, AND JUST THE PART IS 500 DOLLARS?!? THIS COULD OF ENDED VERY BADLY AND I HAVE HAD NOTHING BUT ISSUES WITH THIS PIECE OF JUNK. THE PAINT IS PEELING OFF, LOOKS LIKE NO PRIMER OR SEALER WAS USED IT LITERALLY IS FLAKING OFF ON THE HOOD AND REAR GATE RIGHT WHERE YOU WOULD PUT YOUR HANDS TO OPEN IT. IN THE MANUAL IN VERY SMALL PRINT IT SAYS THE OIL FROM YOUR FINGERS MAY CAUSE PAINT TO CORRODE, ARE YOU KIDDING ME??? YOUR NOT SUPPOSED TO OPEN YOUR HOOD OR TAILGATE??? RIDICULOUS!! THIS VEHICLE IN MY OPINION IS A LEMON!! *TR
NHTSA ODI #10584466
113,000 miles · Apr 23, 2014
Electrical SystemEngine
WAS DRIVING DOWN THE ROAD WHEN EXPEDITION STARTED TO LURCH AND NOT SHIFT PROPERLY. TOOK IT IN TO AUTO SHOP AND THEY DIAGNOSED THAT PISTONS 3 AND 7 WERE MISFIRING. WENT TO CHANGE SPARK PLUGS AND PLUGS BROKE OFF IN THE ENGINE. HAD TO ORDER SPECIAL TOOL TO REMOVE THEM, SECOND TIME THEY HAVE HAD TO BE REPLACED BOTH TIMES THEY HAVE B…
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WAS DRIVING DOWN THE ROAD WHEN EXPEDITION STARTED TO LURCH AND NOT SHIFT PROPERLY. TOOK IT IN TO AUTO SHOP AND THEY DIAGNOSED THAT PISTONS 3 AND 7 WERE MISFIRING. WENT TO CHANGE SPARK PLUGS AND PLUGS BROKE OFF IN THE ENGINE. HAD TO ORDER SPECIAL TOOL TO REMOVE THEM, SECOND TIME THEY HAVE HAD TO BE REPLACED BOTH TIMES THEY HAVE BROKEN OFF. COST WAS OVER 1500.00 *TR
ON CERTAIN TRUCKS, PASSENGER CARS AND SPORT UTILITY VEHICLES, THE WINDSHIELD WIPER MOTOR MAY HAVE BEEN PRODUCED WITHOUT GREASE BEING APPLIED TO THE OUTPUT SHAFT GEAR.
Consequence & remedy
Consequence: AFTER A PERIOD OF CONTINUOUS USE ON THE HIGH SPEED SETTING, LACK OF GREASE ON THE OUTPUT SHAFT GEAR MAY CAUSE THE GEAR TO DISTORT OR FRACTURE DURING OPERATION RESULTING IN A LOSS OF WIPER FUNCTION. INOPERATIVE WIPERS UNDER INCLEMENT WEATHER CONDITIONS COULD CAUSE A CRASH DUE TO IMPAIRED VISIBILITY.
Remedy: DEALERS WILL INSPECT THE WIPER MOTOR FOR THE PRESENCE OF GREASE AND GREASE THE WIPER MOTOR GEARS IF NECESSARY. THE RECALL BEGAN ON NOVEMBER 22, 2005. OWNERS MAY CONTACT FORD AT 1-800-392-3673 OR LINCOLN/MERCURY AT 1-800-521-4140.
ON CERTAIN SPORT UTILITY VEHICLES, THE FRONT AND REAR TIRES ON THE DRIVER'S SIDE OF AFFECTED VEHICLES MAY HAVE BEEN DAMAGED AT THE CENTER TREAD DURING PRODUCTION.
Consequence & remedy
Consequence: OVER TIME, THE DAMAGE MAY BE SUFFICIENT TO ALLOW BELT CORROSION ULTIMATELY LEADING TO A TREAD SEPARATION, WHICH COULD RESULT IN A CRASH.
Remedy: DEALERS WILL INSPECT ALL FOUR TIRES (TO ENSURE INSPECTION OF THE LEFT HAND SIDE TIRES THAT MAY HAVE BEEN ROTATED TO THE OTHER SIDE OF THE VEHICLE) FOR TIRE TREAD DAMAGE AND, IF NECESSARY, REPLACE THE DAMAGED TIRE. THE RECALL BEGAN ON JULY 13, 2005. OWNERS MAY CONTACT FORD AT 1-800-392-3673.
Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗
NHTSA investigations
1
PE08070 · 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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