NHTSA owner reports · September 18, 2026 snapshot.
Engine And Engine Cooling complaints
75 reportsClear category filter76,000 miles · May 13, 2010
Electronic Stability Control (esc)Engine And Engine Cooling
MY FAMILY, WHICH I HAVE FIVE CHILDREN IN THE TRUCK. ON 10FWY ON MOTHERS DAY EXPEDITION LOST POWER IN SECOND LANE 65MPH FLOWING W/ TRAFFIC. WE MANAGED TO GET IN EMERGENCY LANE. HAD NO IDEA WHAT WAS HAPPENING! AMBER LIGHT APPEARS (WRENCH)?? CLUELESS. PUT TRUCK IN "PARK" TURNED OFF TRUCK WAITED 5 MINUTES. TRUCK STARTED?? DROVE H…
Read full complaint
MY FAMILY, WHICH I HAVE FIVE CHILDREN IN THE TRUCK. ON 10FWY ON MOTHERS DAY EXPEDITION LOST POWER IN SECOND LANE 65MPH FLOWING W/ TRAFFIC. WE MANAGED TO GET IN EMERGENCY LANE. HAD NO IDEA WHAT WAS HAPPENING! AMBER LIGHT APPEARS (WRENCH)?? CLUELESS. PUT TRUCK IN "PARK" TURNED OFF TRUCK WAITED 5 MINUTES. TRUCK STARTED?? DROVE HOME AS TRUCK IS NOT UNSAFE. PARKED TRUCK FOR 3-DAYS NOW TRUCK WILL NOT TURN ON. DEALER WILL LOOK AT TRUCK FOR CHARGE OF COURSE. *TR
NHTSA ODI #10330326
83,968 miles · May 3, 2010
Engine And Engine CoolingVehicle Speed Control
DRIVING TO WORK VIA FREEWAY, HAD JUST REACHED THE BOTTOM OF A FREEWAY OFF-RAMP, AT A STOPLIGHT. LIGHT TURNED GREEN, HAD JUST STARTED TO GO AND THE "FAIL SAFE ENGINE MODE" LIGHT ON MY 2006 FORD EXPEDITION CAME ON THE DASHBOARD, WITHIN 5 SECONDS THE CAR TURNED OFF ON ITS OWN, LIKE TAKING THE KEY OUT OF THE IGNITION. HAD IT TOWED …
Read full complaint
DRIVING TO WORK VIA FREEWAY, HAD JUST REACHED THE BOTTOM OF A FREEWAY OFF-RAMP, AT A STOPLIGHT. LIGHT TURNED GREEN, HAD JUST STARTED TO GO AND THE "FAIL SAFE ENGINE MODE" LIGHT ON MY 2006 FORD EXPEDITION CAME ON THE DASHBOARD, WITHIN 5 SECONDS THE CAR TURNED OFF ON ITS OWN, LIKE TAKING THE KEY OUT OF THE IGNITION. HAD IT TOWED TO A FORD DEALERSHIP, THEY RAN DIAGNOSTICS, SAID THE THROTTLE BODY ASSEMBLY NEEDED REPLACING. I LOOKED ON THE INTERNET, GOOGLING "FAIL SAFE ENGINE MODE" AND "FORD" AND FOUND THIS TO BE A COMMON PROBLEM. ASKED WHY IT'S NOT A RECALL ITEM OR HAS A TECHNICAL BULLETIN WITH SO MANY CASES OF IT, PLUS IT'S VERY DANGEROUS. MANY IN THEIR INTERNET POSTINGS SAID THE PROBLEM COMES BACK. DEALERSHIP SAID TO CONTACT FORD CORPORATE, OPENED A CUDL CASE FOR ME TO REQUEST REIMBURSEMENT. WROTE A LETTER TO FORD CORPORATE, INCLUDED INTERNET LINKS TO ALL THE POSTINGS OF OTHER PEOPLE HAVING THE SAME PROBLEM, ASKED FOR $480.35 REIMBURSEMENT, ALSO ASKED WHAT THEY ARE DOING ABOUT THIS DANGEROUS SITUATION WITH THE THROTTLE BODY ASSEMBLY. FORD CORPORATE SEND ME A LETTER BACK, SIMPLY SAID I'M PAST WARRANTY AND UNABLE TO PROVIDE REIMBURSEMENT. THEY DID NOT REPLY REGARDING MY QUESTION ABOUT WHAT'S BEING DONE ABOUT THIS DANGEROUS PROBLEM. *TR
NHTSA ODI #10328713
99,000 miles · Apr 9, 2010
Engine And Engine Cooling
2006 FORD EXPEDITION FAILSAFE MODE COMES ON. IT HAS HAPPENED 4 TIMES IN 4 MONTHS. HAVE LOSS OF STEERING AND ENGINE HAS NO POWER. VERY DANGEROUS. *TR
NHTSA ODI #10324757
40,000 miles · Mar 19, 2010
Engine And Engine Cooling
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. WHILE DRIVING IN A PARKING LOT AT ABOUT 15MPH, THE VEHICLE JUST SHUT OFF. A LIGHT ON THE INSTRUMENT PANEL INDICATED THAT THE VEHICLE WAS IN " ENGINE FAIL SAFE MODE". THE CONTACT PUT HER HAZARD LIGHTS ON, PUT THE VEHICLE IN PARK AND TURNED THE ENGINE OFF. SHE RESTARTED THE VEHICLE A…
Read full complaint
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. WHILE DRIVING IN A PARKING LOT AT ABOUT 15MPH, THE VEHICLE JUST SHUT OFF. A LIGHT ON THE INSTRUMENT PANEL INDICATED THAT THE VEHICLE WAS IN " ENGINE FAIL SAFE MODE". THE CONTACT PUT HER HAZARD LIGHTS ON, PUT THE VEHICLE IN PARK AND TURNED THE ENGINE OFF. SHE RESTARTED THE VEHICLE AND IT OPERATED NORMALLY. THE CONTACT STATED THAT THIS HAS HAPPENED ABOUT 6-7 TIMES. SHE REPORTED THE FAILURE TO THE MANUFACTURER AND THEY STATED THAT THEY NEVER HEARD OF ANYTHING LIKE THIS. THE DRIVER DOES NOT FEEL HER VEHICLE IS SAFE. THE FAILURE MILEAGE WAS 40,000 AND THE CURRENT MILEAGE IS 52,691.
NHTSA ODI #10320956
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…
Read full complaint
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
38,000 miles · Feb 24, 2010
Engine And Engine Cooling
TL*THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT THE FAIL SAFE MODE WAS ACTIVATED AND MADE IT IMPOSSIBLE TO CONTINUE DRIVING AFTER THE VEHICLE WAS STOPPED. THE VEHICLE WOULD NOT ACCELERATE OR TURN IN ANY DIRECTION. IF THE VEHICLE WAS TURNED OFF AND RESTARTED THE VEHICLE WOULD FUNCTION PROPERLY. THE VEHICLE MAL…
Read full complaint
TL*THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT THE FAIL SAFE MODE WAS ACTIVATED AND MADE IT IMPOSSIBLE TO CONTINUE DRIVING AFTER THE VEHICLE WAS STOPPED. THE VEHICLE WOULD NOT ACCELERATE OR TURN IN ANY DIRECTION. IF THE VEHICLE WAS TURNED OFF AND RESTARTED THE VEHICLE WOULD FUNCTION PROPERLY. THE VEHICLE MALFUNCTIONED WHENEVER THE VEHICLE WAS PULLING OFF FROM A STOP. THE VEHICLE HAD 38,000 AT THE TIME OF THE FAILURE AND THE CURRENT MILEAGE WAS 38,500 CURRENT MILES.
NHTSA ODI #10313559
93,000 miles · Dec 4, 2009
Engine And Engine Cooling
DRIVING VEHICLE AND CAR SHUT OFF. A WRENCH SYMBOL APPEARED. AFTER 2 ATTEMPTS, I WAS ABLE TO GET THE VEHICLE RESTARTED. TOOK CAR TO GARAGE FOR SERVICE AND WAS INFORMED THAT THE COMPUTER CODE WHICH CAME BACK WAS THE "CRUISE CONTROL CIRCUITRY" AND I WOULD NEED TO TAKE THE VEHICLE TO A FORD DEALERSHIP FOR SERVICE DUE TO THE NATUR…
Read full complaint
DRIVING VEHICLE AND CAR SHUT OFF. A WRENCH SYMBOL APPEARED. AFTER 2 ATTEMPTS, I WAS ABLE TO GET THE VEHICLE RESTARTED. TOOK CAR TO GARAGE FOR SERVICE AND WAS INFORMED THAT THE COMPUTER CODE WHICH CAME BACK WAS THE "CRUISE CONTROL CIRCUITRY" AND I WOULD NEED TO TAKE THE VEHICLE TO A FORD DEALERSHIP FOR SERVICE DUE TO THE NATURE OF THE REPAIR. *TR
NHTSA ODI #10294525
50,000 miles · Nov 17, 2009
Engine And Engine Cooling
I HAVE A 2006 FORD EXPEDITION WITH 50,000 MILES ON IT. MY WIFE DRIVES THIS CAR WITH OUR CHILDREN. ABOUT 7 OR 8 TIMES NOW THE CHECK ENGINE OR (WRENCH LIGHT) COMES ON GOING DOWN THE ROAD AND SHUTS THE CAR OFF COMPLETELY. I HAVE LOOKED ONLINE AND HAVE SEEN THAT THOUSANDS OF PEOPLE ARE HAVING THE SAME THING HAPPEN TO THEM. FROM WHAT…
Read full complaint
I HAVE A 2006 FORD EXPEDITION WITH 50,000 MILES ON IT. MY WIFE DRIVES THIS CAR WITH OUR CHILDREN. ABOUT 7 OR 8 TIMES NOW THE CHECK ENGINE OR (WRENCH LIGHT) COMES ON GOING DOWN THE ROAD AND SHUTS THE CAR OFF COMPLETELY. I HAVE LOOKED ONLINE AND HAVE SEEN THAT THOUSANDS OF PEOPLE ARE HAVING THE SAME THING HAPPEN TO THEM. FROM WHAT I READ IT HAS SOMETHING TO DO WITH THE ELECTRONIC THROTTLE CONTROL. I KNOW YOU PROBABLY GET COMPLAINTS ALL THE TIME BUT THIS IS VERY SERIOUS. EVERY POST ON THE WEB SAYS THAT FORD HAS NO RECALL AND THAT THE DEALERSHIPS ARE DOING NOTHING TO FIX THIS PROBLEM BUT PUTTING A NEW PART ON AND CHARGING FOR IT. THIS IS ABSOLUTELY RIDICULOUS. THERE IS OBVIOUSLY A PROBLEM. PLEASE HELP ME AND OTHERS TO FIX THIS PROBLEM BEFORE SOMEONE GETS HURT. *TR
NHTSA ODI #10292617
48,000 miles · Jul 15, 2009
Engine And Engine Cooling
ENGINE FAILURE OF 2006 FORD EXPEDITION. DEALERSHIP EXPLAINED THE ENGINE HAD A BENT INJECTOR ROD . ADVISED NEW ENGINE WAS NECESSARY. COST ESTIMATE $4000-$7000. *TR
NHTSA ODI #10276889
66,000 miles · Jun 19, 2009
Engine And Engine CoolingInjury
TL*THE CONTACT OWNS A 2006 FORD EXPEDITION. WHILE DRIVING 20 MPH, THE VEHICLE STALLED. THE ENGINE WARNING LIGHT ILLUMINATED ON THE INSTRUMENT PANEL AND READ, "ENGINE FAIL SAFE MODE." AFTER SEVERAL ATTEMPTS, THE CONTACT WAS ABLE TO RESTART THE VEHICLE. THE DEALER REPLACED THE THROTTLE BODY ASSEMBLY. AFTER THE REPAIR, THE CON…
Read full complaint
TL*THE CONTACT OWNS A 2006 FORD EXPEDITION. WHILE DRIVING 20 MPH, THE VEHICLE STALLED. THE ENGINE WARNING LIGHT ILLUMINATED ON THE INSTRUMENT PANEL AND READ, "ENGINE FAIL SAFE MODE." AFTER SEVERAL ATTEMPTS, THE CONTACT WAS ABLE TO RESTART THE VEHICLE. THE DEALER REPLACED THE THROTTLE BODY ASSEMBLY. AFTER THE REPAIR, THE CONTACT BEGAN SMELLING A BURNING OIL ODOR IN THE VEHICLE. THE SMELL BECAME STRONGER AND THEN TURNED INTO A GASEOUS ODOR, WHICH WAS ALSO ENTERING THROUGH THE INTERIOR VENTS. THE CONTACT INSPECTED THE VEHICLE, BUT COULD NOT LOCATE ANY GAS LEAK. THE ODOR BECAME SO OVERPOWERING THAT ONE OF THE OCCUPANTS HAD A NOSE BLEED AND SEVERAL OTHER OCCUPANTS SUFFERED HEADACHES AND STOMACH ACHES. THE DEALER STATED THAT THE OIL LEVEL WAS TOO HIGH AND CAUSED THE FUEL ODOR. THE ODOR IS STILL PRESENT. THE CURRENT AND FAILURE MILEAGES WERE LESS THAN 66,000.
NHTSA ODI #10274331
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
Illustration