NHTSA owner reports · September 18, 2026 snapshot.
Service Brakes, Hydraulic complaints
11 reportsClear category filter10,756 miles · Apr 20, 2012
Latches/locks/linkagesPower TrainService Brakes, Hydraulic
2006 FORD EXPEDITION LIMITED. CONSUMER WRITES IN REGARDS WARRANTY REPAIR DISPUTE AND DRIVER'S SIDE POWER WINDOW BEING EXTREMELY SLOW IN THE CLOSING OPERATION *TGW THE DEALER LUBED THE WINDOW AND STATED THERE WAS NO PROBLEM FOUND. AFTER COMPLAINING SEVERAL TIMES ABOUT THE WINDOW, THE DEALER FINALLY DETERMINED THERE WAS A PROBLEM…
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2006 FORD EXPEDITION LIMITED. CONSUMER WRITES IN REGARDS WARRANTY REPAIR DISPUTE AND DRIVER'S SIDE POWER WINDOW BEING EXTREMELY SLOW IN THE CLOSING OPERATION *TGW THE DEALER LUBED THE WINDOW AND STATED THERE WAS NO PROBLEM FOUND. AFTER COMPLAINING SEVERAL TIMES ABOUT THE WINDOW, THE DEALER FINALLY DETERMINED THERE WAS A PROBLEM. HOWEVER, THE CONSUMER WAS INFORMED THE PARTS AND LABOR WERE NOT COVERED UNDER THE EXTENDED WARRANTY. THE CONSUMER STATED THE PROBLEM EXISTED GOING BACK TO DEC 11, 2006 AND THE DEFECT WAS NOT ADDRESSED OR CORRECTED WHILE THE VEHICLE WAS UNDER THE ORIGINAL FACTORY WARRANTY. THE CONSUMER STATED HE SHOULD NOT BE RESPONSIBLE FOR REPAIRS THAT WERE CALLOUSLY OVERLOOKED AND IGNORED BY THE DEALER. ALSO, THE LOWER RADIATOR SUPPORT TO THE BODY MOUNT WAS SEVERELY RUSTED AND SHOWED SIGNS OF ACTUAL MATERIAL FAILURE. THE CONSUMER STATED THE CONDITION CAN AND WILL EVOLVE INTO THE ROOT CAUSE OF BOTH MECHANICAL AND SAFETY RELATED FAILURES. THE MAJOR BODY AND FRONT FRAME SUPPORT FAILING UNDER DRIVING CONDITIONS COULD LEAD TO ENGINE FAILURE, AND LOSS OF CONTROL OF THE VEHICLE. THE MOST SERIOUS SAFETY CONCERN, WAS THE FRONT BRAKE LINES WHICH WERE SHOWING SIGNS OF SERIOUS RUST. THE DEALER INFORMED THE CONSUMER THE LINES COULD ONLY BE REPLACED UNDER WARRANTY IF THERE WERE SIGNS OF LEAKAGE. THE CONSUMER STATED CORROSION IN THE FORM OF RUST WOULD COMPROMISE THE INTEGRITY OF THE STEEL BRAKE LINES, ALLOWING BRAKE FLUID TO LEAK OUT RESULTING IN A TOTAL LOSS OF BRAKING POWER. THE LEFT REAR DOOR WOULD NOT OPEN FROM THE INSIDE, THE DRIVER'S FRONT DOOR HAD TO BE SLAMMED IN ORDER FOR IT TO CLOSE PROPERLY, THE FRONT AXLE DRIVE PINION WAS LEAKING AND HAD TO BE REPLACED.*JB
NHTSA ODI #10456236
66,710 miles · Sep 22, 2010
Service Brakes, Hydraulic
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT WAS TRAVELING 35 MPH WHEN THE BRAKES ON THE VEHICLE FAILED. THE VEHICLE WAS TAKEN TO THE DEALER, AND THE CONTACT WAS ADVISED THAT THE BRAKE LINES HAD RUSTED THROUGH. THE MANUFACTURER STATED THAT CORROSION DAMAGE TO THE VEHICLE IS WHAT CAUSED THE BRAKE FAILURE. THE CONTA…
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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT WAS TRAVELING 35 MPH WHEN THE BRAKES ON THE VEHICLE FAILED. THE VEHICLE WAS TAKEN TO THE DEALER, AND THE CONTACT WAS ADVISED THAT THE BRAKE LINES HAD RUSTED THROUGH. THE MANUFACTURER STATED THAT CORROSION DAMAGE TO THE VEHICLE IS WHAT CAUSED THE BRAKE FAILURE. THE CONTACT HAS FILED A COMPLAINT WITH THE MANUFACTURER. THE CONTACT FEELS THAT THE CORROSION SHOULD NOT BE A FACTOR BECAUSE THEY DO NOT LIVE IN A SNOW ENVIRONMENT. THE FAILURE MILEAGE 66710 AND THE CURRENT MILEAGE 68000.
NHTSA ODI #10356959
46,000 miles · Jul 7, 2010
EquipmentService Brakes, Hydraulic
I HAVE A 2006 FORD EXPEDITION AND MY WIFE ALMOST LOST CONTROL AND HIT A CAR WHEN THE BRAKES WENT TO THE FLOOR. THE VEHICLE HAS HAD "SPONGY BRAKES" SINCE I BOUGHT IT AND HAD IT TO THE DEALER TWICE. THERE IS A TSB TO REPLACE THE FRONT CALIPER/ROTOR AND PADS AND FORD DID THIS BUT IT STILL FEELS SPONGY AND IS NOW LEAKING FLUID. T…
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I HAVE A 2006 FORD EXPEDITION AND MY WIFE ALMOST LOST CONTROL AND HIT A CAR WHEN THE BRAKES WENT TO THE FLOOR. THE VEHICLE HAS HAD "SPONGY BRAKES" SINCE I BOUGHT IT AND HAD IT TO THE DEALER TWICE. THERE IS A TSB TO REPLACE THE FRONT CALIPER/ROTOR AND PADS AND FORD DID THIS BUT IT STILL FEELS SPONGY AND IS NOW LEAKING FLUID. THIS HAS BEEN AN ISSUE ON MANY EXPEDITIONS AND SHOULD HAVE BEEN A RECALL RATHER THAN A TSB. THIS IS AN INCREDIBLY DANGEROUS SITUATION WHEN THE BRAKES FAIL. I KNOW I HAVE HAD INSTANCES WHERE I LITERALLY NEED TO STAND ON THE BRAKES TO GET THE VEHICLE TO STOP. *TR
NHTSA ODI #10341811
48,000 miles · Aug 27, 2008
Engine And Engine CoolingService Brakes, Hydraulic
AUGUST 21 ON THE WAY TO WORK (4 MILE DRIVE) THE TRUCK STARTED TO SHAKE AND LOST POWER,CHECK ENGINE LIGHT CAME ON, WE TOOK THE TRUCK TO THE DEALER,AND THEY CAN NOT FIGURE WHAT IS GOING ON,SO THEY SAID THE ENGINE NEEDS TO BE REPLACED. THE CODES ARE P0022-P0305-P0307-P1184-P2198-P2273 MY FAMILY JUST CAME BACK FROM A 3000 TRIP ,I…
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AUGUST 21 ON THE WAY TO WORK (4 MILE DRIVE) THE TRUCK STARTED TO SHAKE AND LOST POWER,CHECK ENGINE LIGHT CAME ON, WE TOOK THE TRUCK TO THE DEALER,AND THEY CAN NOT FIGURE WHAT IS GOING ON,SO THEY SAID THE ENGINE NEEDS TO BE REPLACED. THE CODES ARE P0022-P0305-P0307-P1184-P2198-P2273 MY FAMILY JUST CAME BACK FROM A 3000 TRIP ,I CAN ONLY IMAGINE HAVING THIS HAPPENING TO US DURING THIS TIME. I BEEN LOOKING FOR THE SAME TYPE OF TROUBLE TO THIS TRUCKS AND FOUND THAT THERE IS A NUMBER OF SIMILAR COMPLAINTS ABOUT HAVING TO REPLACE ENGINES RANGING FROM 38,000 MILES TO ABOUT 60,000MILES. THE PRICE OF THIS CARS ARE WELL OVER $35,000 TO HAVING TO SPEND ANOTHER $7,000 WITH ALL THE PROBLEMS OF OUR ECONOMY RIGHT NOW A NORMAL PERSON LIKE ME CAN NOT AFFORD ANOTHER RIP OFF BY ONE OF THE BIG COMPANIES,LIKE FORD. ALL I'M ASKING IS THAT THEY TAKE RESPONSIBILITY FOR THIS ENGINE TROUBLES AND REPAIR LIKE THEY SUPPOSED TO. *TR
NHTSA ODI #10240001
15,000 miles · Dec 6, 2007
Electronic Stability Control (esc)Power TrainService Brakes, Hydraulic
NO INCIDENT YET. VEHICLES TRACTION CONTROL FAILS, ABS FAILS AND 4 WHEEL DRIVE FAILS ALL AT THE SAME TIME. *TR
NHTSA ODI #10211048
36,700 miles · Oct 16, 2007
Service Brakes, Hydraulic
THE VEHICLE SMELLED LIKE IT WAS ON FIRE UP FRONT IN THE ENGINE COMPARTMENT. THE FRONT TIRE WERE EXTREMELY HOT. MY WIFE DID NOT HAVE ANY BRAKES TO AMOUNT TO ANYTHING WHEN SHE PRESSED THE BRAKE PEDAL TO STOP. THE DEALERSHIP STATED THAT THE BRAKE MASTER CYLINDER WAS BAD. THEY REPLACED THE BRAKE MASTER CYLINDER. *TR
NHTSA ODI #10205885
13,000 miles · Jun 11, 2007
Service Brakes, HydraulicCrashInjury
TL*THE CONTACT OWNS A 2006 FORD EXPEDITION. WHILE ATTEMPTING TO STOP THE VEHICLE, THE BRAKE PEDAL EXTENDED TO THE FLOOR. ON NOVEMBER 6, 2006, THE CONTACT WAS UNABLE TO ENGAGE THE BRAKES AND CRASHED INTO A VEHICLE. THE CONTACT WAS INJURED AND THE AIR BAGS DEPLOYED. THERE WERE NO PASSENGERS IN THE VEHICLE AT THE TIME. THE MOST RE…
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TL*THE CONTACT OWNS A 2006 FORD EXPEDITION. WHILE ATTEMPTING TO STOP THE VEHICLE, THE BRAKE PEDAL EXTENDED TO THE FLOOR. ON NOVEMBER 6, 2006, THE CONTACT WAS UNABLE TO ENGAGE THE BRAKES AND CRASHED INTO A VEHICLE. THE CONTACT WAS INJURED AND THE AIR BAGS DEPLOYED. THERE WERE NO PASSENGERS IN THE VEHICLE AT THE TIME. THE MOST RECENT FAILURE OCCURRED ON JUNE 1, 2007. THE VEHICLE WAS REPAIRED AND MOST OF THE BRAKING SYSTEM WAS REPLACED. A MONTH LATER THE ANOTHER CRASH OCCURRED WHILE DRIVING 25MPH AND ATTEMPTING TO ENGAGE THE BRAKE PEDAL. THERE WERE NO INJURIES. THE TOTAL COST OF REPAIRS WERE $2,300. THE VEHICLE IS EQUIPPED WITH AN ELECTRONIC STABILITY THAT TAKES OVER AND IT LEAVES THE CONTACT WITH NO CONTROL OF THE BRAKING SYSTEM. THE DEALER STATED THAT HE WAS ALSO UNABLE TO DIAGNOSE THE RECENT FAILURE AND THERE WERE NO INDICATIONS FROM THE COMPUTER CODES. THERE WERE A TOTAL OF 4 VEHICLES INVOLVED IN THE CRASH AND 3 OF THEM WERE DAMAGED INCLUDING THE CONTACTS VEHICLE. THE CURRENT MILEAGE WAS 19,783 AND THE FAILURE MILEAGE WAS 13,000.
NHTSA ODI #10192941
28,000 miles · Mar 19, 2007
Service Brakes, Hydraulic
FRONT ROTORS TURNED BY DEALER SEVERAL WEEKS PRIOR DUE TO VIBRATION WHEN STOPPING. SAME PROBLEM RETURNED AND DEALER THIS TIME REPLACED ROTORS AND CALIPERS. NOW BRAKES FEEL WEAK, AND TRAVEL OF PEDAL HAS INCREASED BEFORE BRAKES ENGAGE. DEALER CLAIMS THIS IS WITHIN NORMAL OPERATION . DEALER CLAIMS NEW CALIPERS HAVE LARGER PISTON SO …
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FRONT ROTORS TURNED BY DEALER SEVERAL WEEKS PRIOR DUE TO VIBRATION WHEN STOPPING. SAME PROBLEM RETURNED AND DEALER THIS TIME REPLACED ROTORS AND CALIPERS. NOW BRAKES FEEL WEAK, AND TRAVEL OF PEDAL HAS INCREASED BEFORE BRAKES ENGAGE. DEALER CLAIMS THIS IS WITHIN NORMAL OPERATION . DEALER CLAIMS NEW CALIPERS HAVE LARGER PISTON SO THIS IS REASON FOR INCREASED PEDEL TRAVEL AND DIFFERENT FEEL OF BRAKES ? BRAKES DO NOT FEEL AS IF STOPPING VEHICLE AS BEFORE PROBLEM BEGAN . RETURNED AGAIN TO ASK DEALER 3-19-07 TO BLEED SYSTEM DUE TO SOFT PEDAL AND CONCERN. SYSTEM BLED MANUALLY THIS TIME AND PEDAL GOT SOME WHAT BETTER . STILL NOT AS FIRM AS WHEN PROBLEM STARTED. PEDAL TRAVEL INCREASE IS STILL PRESENT BEFORE BRAKES ENGAGE. VEH DOES NOT STOP AS WELL AS BEFORE PROBLEM BEGAN .
NHTSA ODI #10185594
13,000 miles · Jan 28, 2007
Service Brakes, HydraulicCrashInjury
BRAKES FAILED IN PANIC SITUATION ON DRY ROAD. BRAKES GRABBED AND THEN COMPLETELY LET GO WHEN ANTILOCK SYSTEM TOOK OVER. THERE WAS NO SURGE IN THE PEDAL AS IT WENT COMPLETELY TO THE FLOOR. MY ROAD SPEED WAS 35 MPH WHEN I HIT THE BRAKES AND I WOULD SAY THEIR WAS AT LEAST 100FT BETWEEN MINE AND THE STOPPED VEHICLE IN FRONT OF ME…
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BRAKES FAILED IN PANIC SITUATION ON DRY ROAD. BRAKES GRABBED AND THEN COMPLETELY LET GO WHEN ANTILOCK SYSTEM TOOK OVER. THERE WAS NO SURGE IN THE PEDAL AS IT WENT COMPLETELY TO THE FLOOR. MY ROAD SPEED WAS 35 MPH WHEN I HIT THE BRAKES AND I WOULD SAY THEIR WAS AT LEAST 100FT BETWEEN MINE AND THE STOPPED VEHICLE IN FRONT OF ME. I THOUGHT OF SWERVING TO MISS IT BUT WAS SURE I WOULD AT LEAST SLOW ENOUGH TO ONLY BUMP THE VEC. IN FRONT OF ME. THE GUY I HIT SAID HE HEARD A CHIRP AND A COUPLE SECONDS LATER GOT HIT. THERE WHERE NO SKID MARKS THAT I KNOW OF. THEIR WAS 21000 DOLLARS DAMAGE TO THE FRONT OF MY 2006 EXPIDITION. *NM
NHTSA ODI #10180943
62,000 miles · Mar 10, 2006
Service Brakes, Hydraulic
DT*: THE CONTACT STATED WHILE DRIVING ON ICE AT VARIOUS SPEEDS, THE BRAKES LOCK UP. THE VEHICLE HAS BEEN TO THE DEALERSHIP, AND THE MANUFACTURER DETERMINED THIS IS HOW THE ADVANCE TRACK BRAKING SYSTEM IS MANUFACTURED.
NHTSA ODI #10152411
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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