NHTSA owner reports · September 18, 2026 snapshot.
Engine And Engine Cooling complaints
75 reportsClear category filter160,000 miles · Jan 18, 2012
Engine And Engine Cooling
TL* THE CONTACT OWN A 2006 FORD EXPEDITION. THE CONTACT STATED WAS DRIVING 25 MPH WHEN THE VEHICLE STALLED WITHOUT WARNING. THE VEHICLE WAS RESTARTED AND THE CONTACT DROVE THE VEHICLE HOME. THE CONTACT ATTEMPTED TO RESTART THE VEHICLE BUT TO NO AVAIL. THE CONTACT HAD THE VEHICLE TOWED TO A DEALER WHERE THE DEALER REPLACED THE…
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TL* THE CONTACT OWN A 2006 FORD EXPEDITION. THE CONTACT STATED WAS DRIVING 25 MPH WHEN THE VEHICLE STALLED WITHOUT WARNING. THE VEHICLE WAS RESTARTED AND THE CONTACT DROVE THE VEHICLE HOME. THE CONTACT ATTEMPTED TO RESTART THE VEHICLE BUT TO NO AVAIL. THE CONTACT HAD THE VEHICLE TOWED TO A DEALER WHERE THE DEALER REPLACED THE CAM PHASERS. THE FAILURE MILEAGE WAS 160,000. THE VIN WAS NOT AVAILABLE.
NHTSA ODI #10444400
86,280 miles · Jan 6, 2012
Engine And Engine CoolingVehicle Speed Control
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING 15 MPH ON THE HIGHWAY, THE VEHICLE UNEXPECTEDLY STALLED. AN ENGINE FAIL SAFE LIGHT ALSO BEGAN TO ILLUMINATE ON THE INSTRUMENT PANEL. BOTH THE DEALER AND MANUFACTURER WERE NOTIFIED, BUT DENIED ANY ASSISTANCE WITH REPAIRS OF THE FAILURE. THE VEHICLE…
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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING 15 MPH ON THE HIGHWAY, THE VEHICLE UNEXPECTEDLY STALLED. AN ENGINE FAIL SAFE LIGHT ALSO BEGAN TO ILLUMINATE ON THE INSTRUMENT PANEL. BOTH THE DEALER AND MANUFACTURER WERE NOTIFIED, BUT DENIED ANY ASSISTANCE WITH REPAIRS OF THE FAILURE. THE VEHICLE WAS ON 01/06/12 AT THE CONTACT'S EXPENSE. THE APPROXIMATE FAILURE AND CURRENT MILEAGES WERE 86,280. THE THROTTLE BODY AND MOTOR ASSEMBLY WERE REPLACED. UPDATED 06/27/12*JB
NHTSA ODI #10442650
90,000 miles · Dec 23, 2011
Engine And Engine Cooling
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. WHILE DRIVING APPROXIMATELY 40 MPH, THE ENGINE STALLED WITH THE ILLUMINATION OF THE CHECK ENGINE WARNING INDICATOR. THE ENGINE RESTARTED AFTER WAITING A FEW MOMENTS. THE SAME FAILURE RECURRED FOUR TIMES. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER AND THEY WERE UNABLE TO DUPLICATE T…
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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. WHILE DRIVING APPROXIMATELY 40 MPH, THE ENGINE STALLED WITH THE ILLUMINATION OF THE CHECK ENGINE WARNING INDICATOR. THE ENGINE RESTARTED AFTER WAITING A FEW MOMENTS. THE SAME FAILURE RECURRED FOUR TIMES. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER AND THEY WERE UNABLE TO DUPLICATE THE PROBLEM. THE MANUFACTURER WAS NOTIFIED OF THE MALFUNCTION. THE APPROXIMATE FAILURE MILEAGE WAS 90,000.
NHTSA ODI #10441128
117,000 miles · Dec 15, 2011
Engine And Engine Cooling
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT WHEN DRIVING AT VARIOUS SPEEDS, THE ENGINE SAFETY MODE FAILURE WARNING LAMP WOULD ILLUMINATE AND THE VEHICLE WOULD STALL. THE CONTACT MENTIONED THAT THE FAILURE OCCURRED THREE TIMES. THE VEHICLE WAS TAKEN TO THE DEALER WHO WAS UNABLE TO DUPLICATE THE FAILURE. T…
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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT WHEN DRIVING AT VARIOUS SPEEDS, THE ENGINE SAFETY MODE FAILURE WARNING LAMP WOULD ILLUMINATE AND THE VEHICLE WOULD STALL. THE CONTACT MENTIONED THAT THE FAILURE OCCURRED THREE TIMES. THE VEHICLE WAS TAKEN TO THE DEALER WHO WAS UNABLE TO DUPLICATE THE FAILURE. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE AND THE VEHICLE WAS NOT REPAIRED. THE FAILURE AND THE CURRENT MILEAGE WAS 117,000.
NHTSA ODI #10440029
38,000 miles · Nov 28, 2011
Engine And Engine Cooling
A WARNING LIGHT "ENGINE FAIL SAFE" FLASHED AND THE ENGINE STALLED. I WAS FORTUNATE THERE WAS A PARKING LOT I COULD FORCE THE VEHICLE INTO, AS I WAS IN MORNING RUSH HOUR TRAFFIC IN HOUSTON TX, AND WAS ALMOST REAR ENDED. APPARENTLY THIS IS A VERY COMMON PROBLEM AMONG THE 2006 FORD EXPEDITION, I HAVE DONE SOME RESEARCH ON-LINE A…
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A WARNING LIGHT "ENGINE FAIL SAFE" FLASHED AND THE ENGINE STALLED. I WAS FORTUNATE THERE WAS A PARKING LOT I COULD FORCE THE VEHICLE INTO, AS I WAS IN MORNING RUSH HOUR TRAFFIC IN HOUSTON TX, AND WAS ALMOST REAR ENDED. APPARENTLY THIS IS A VERY COMMON PROBLEM AMONG THE 2006 FORD EXPEDITION, I HAVE DONE SOME RESEARCH ON-LINE AND VIEWED MANY COMPLAINTS ABOUT THIS SAME THING. I CHECKED WITH ONE AUTO SHOP, WHICH SAYS THE THROTTLE BODY NEEDS TO BE REPLACED AT A COST OF $800.00, THE FORD DEALER/SERVICE DEPT QUOTED 686.85. THEY BOTH TOLD ME THEY EACH HAVE ANOTHER 2006 EXPEDITION IN THEIR SHOP AT THIS TIME FOR THE SAME REPAIR, AND HAVE HAD SEVERAL REPAIRS FOR THIS SAME ISSUE. I BELIEVE THIS IS A VERY DANGEROUS DEFECT WITH AN ENGINE SHUTTING DOWN WITH ONLY A HALF SECOND NOTICE. I AM GLAD I WAS NOT ON THE FREEWAY (IN HOUSTON!) DOING 60 MPH. MY VEHICLE HAS A LITTLE OVER 38,000 MILES ON IT. *KB
NHTSA ODI #10437574
80,000 miles · Nov 27, 2011
Electrical SystemEngine And Engine CoolingVehicle Speed Control
WHILE DRIVING MY 2006 FORD EXPEDITION EDDIE BAUER, THE ENGINE COMPLETELY SHUTS OFF. SOMETIMES WHILE SITTING IDLE AND OTHER TIMES WHILE DRIVING 70 MPH ON THE INTERSTATE. TONIGHT, WITHIN 1 HOUR THIS HAPPENED ABOUT 15 TIMES WHERE THE ENGINE CUT OFF, I LOST POWER STEERING, HAD TO ROLL OVER TO THE SHOULDER, TURN THE KEY OFF AND BAC…
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WHILE DRIVING MY 2006 FORD EXPEDITION EDDIE BAUER, THE ENGINE COMPLETELY SHUTS OFF. SOMETIMES WHILE SITTING IDLE AND OTHER TIMES WHILE DRIVING 70 MPH ON THE INTERSTATE. TONIGHT, WITHIN 1 HOUR THIS HAPPENED ABOUT 15 TIMES WHERE THE ENGINE CUT OFF, I LOST POWER STEERING, HAD TO ROLL OVER TO THE SHOULDER, TURN THE KEY OFF AND BACK ON TO RESTART...SOMETIMES IT WOULD TAKE UP TO 10 MINUTES TO RESTART. I WAS LUCKY WE WERE NOT HIT FROM BEHIND. I HAVE 2 KIDS IN CARSEATS STILL THAT COULD HAVE BEEN INJURED. RESEARCH ONLINE REVEALS THAT I AM NOT ALONE. THIS IS A VERY DANGEROUS DEFECT THAT COULD GET SOMEBODY KILLED. *TR
NHTSA ODI #10437417
71,200 miles · Nov 23, 2011
Engine And Engine Cooling
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT WAS DRIVING APPROXIMATELY 10 MPH APPROACHING A STOP SIGNAL AND FROM A COMPLETE STOP, THE ENGINE STALLED WHEN THE WARNING LIGHT ILLUMINATED; HOWEVER, THE VEHICLE RESTARTED WITHIN A FEW MINUTES. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC AND WAS CURRENTLY BEING DIAGNOS…
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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT WAS DRIVING APPROXIMATELY 10 MPH APPROACHING A STOP SIGNAL AND FROM A COMPLETE STOP, THE ENGINE STALLED WHEN THE WARNING LIGHT ILLUMINATED; HOWEVER, THE VEHICLE RESTARTED WITHIN A FEW MINUTES. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC AND WAS CURRENTLY BEING DIAGNOSED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 71,200.
NHTSA ODI #10436883
Mileage unknown · Nov 17, 2011
Engine And Engine Cooling
2006 FORD EXPEDITION. CONSUMER STATES MECHANICAL ISSUES WITH THE VEHICLE *TGW THE DEALER INFORMED THE CONSUMER A NEW ENGINE WAS NEEDED. THE WARRANTY DEPT. DENIED THE CONSUMERS CLAIM, BECAUSE MAINTENANCE RECORDS COULD NOT BE PRODUCED. THE CONSUMER'S HOUSE WAS SET ON FIRE, AND THEREFORE, NO MAINTENANCE RECORDS WERE AVAILABLE. …
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2006 FORD EXPEDITION. CONSUMER STATES MECHANICAL ISSUES WITH THE VEHICLE *TGW THE DEALER INFORMED THE CONSUMER A NEW ENGINE WAS NEEDED. THE WARRANTY DEPT. DENIED THE CONSUMERS CLAIM, BECAUSE MAINTENANCE RECORDS COULD NOT BE PRODUCED. THE CONSUMER'S HOUSE WAS SET ON FIRE, AND THEREFORE, NO MAINTENANCE RECORDS WERE AVAILABLE. *JB
NHTSA ODI #10437008
73,000 miles · Nov 14, 2011
Engine And Engine Cooling
THE VEHICLE HAS DONE THIS TWICE. DRIVING ALONG, IT GOES INTO FAIL SAFE MODE AND STOPS DEAD. THE MANUAL STATES THIS IS A COOLANT ISSUE WHICH WAS NOT THE CASE; THERE WAS ADEQUATE COOLANT. DOING SOME RESEARCH ON VARIOUS INTERNET SITES, THIS SEEMS TO BE A COMMON PROBLEM WITH 2006 EXPEDITIONS. I CALLED FORD CUSTOMER SERVICE A…
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THE VEHICLE HAS DONE THIS TWICE. DRIVING ALONG, IT GOES INTO FAIL SAFE MODE AND STOPS DEAD. THE MANUAL STATES THIS IS A COOLANT ISSUE WHICH WAS NOT THE CASE; THERE WAS ADEQUATE COOLANT. DOING SOME RESEARCH ON VARIOUS INTERNET SITES, THIS SEEMS TO BE A COMMON PROBLEM WITH 2006 EXPEDITIONS. I CALLED FORD CUSTOMER SERVICE AND WAS TOLD THEY WERE UNAWARE OF A PROBLEM. I FIND THIS DIFFICULT TO BELIEVE GIVEN ALL THE SITES REPORTING THIS SAME ISSUE. *TR
NHTSA ODI #10435469
80,000 miles · Nov 2, 2011
Engine And Engine Cooling
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT THE VEHICLE WOULD STALL AT ANYTIME WHILE IN MOTION. THE DEALER ATTEMPTED TO REPAIR THE DEFECT, BUT THE FAILURE RECURRED. THE MANUFACTURER WAS NOT CONTACTED. THE FAILURE AND THE CURRENT MILEAGE WAS 80,000. UPDATED 02/22/12*LJ THE CONSUMER STATED THE VEHICL…
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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT THE VEHICLE WOULD STALL AT ANYTIME WHILE IN MOTION. THE DEALER ATTEMPTED TO REPAIR THE DEFECT, BUT THE FAILURE RECURRED. THE MANUFACTURER WAS NOT CONTACTED. THE FAILURE AND THE CURRENT MILEAGE WAS 80,000. UPDATED 02/22/12*LJ THE CONSUMER STATED THE VEHICLE WOULD STALL WHILE AT A STOP. UPDATED 03/01/12
NHTSA ODI #10433992
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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