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2006 Ford Expedition

Owner reports · Recalls · Investigations

Similar to other model years

Owner complaints for the 2006 Ford Expedition do not stand out strongly from the model-year median of 155.

About this comparison →

When problems were reported

Mileage at the reported incident

263 reports with mileage · 36 unknown

NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.

What to inspect

Issues worth paying extra attention to based on owner reports.

  • Engine. Review the 87 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Engine And Engine Cooling. Review the 75 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Electrical System. Review the 32 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

19 crash reports6 fire reports18 injury reports

What owners actually said

299 reports
88,000 miles · Jul 18, 2012
EnginePower Train

ENGINE WAS LOSING POWER UNDER LOAD (ONLY WHILE ACCELERATING). NO CHECK ENGINE LIGHT EVER CAME ON. AT 88,000 MILES FIGURED THAT NOT ONLY WILL I REPLACE ALL 8 SPARK PLUGS, BUT WOULD REPLACE ALL 8 COIL PACKS AS WELL. UPON REMOVAL ON THE SPARK PLUGS, 1 SPARK PLUG BROKE (SO FAR) LEAVING THE BOTTOM PIECE INSIDE THE HEAD. FORD KNOWS AB…

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ENGINE WAS LOSING POWER UNDER LOAD (ONLY WHILE ACCELERATING). NO CHECK ENGINE LIGHT EVER CAME ON. AT 88,000 MILES FIGURED THAT NOT ONLY WILL I REPLACE ALL 8 SPARK PLUGS, BUT WOULD REPLACE ALL 8 COIL PACKS AS WELL. UPON REMOVAL ON THE SPARK PLUGS, 1 SPARK PLUG BROKE (SO FAR) LEAVING THE BOTTOM PIECE INSIDE THE HEAD. FORD KNOWS ABOUT THIS PROBLEM, AS IT CAN LEAD MANY LIKE MYSELF WITH AN OUTRAGEOUS EXPENSE TO PROPERLY REMOVE THE BROKEN SPARK PLUG AND CAN IN THE LONG RUN DAMAGE THE ALUMINUM HEAD TOO. THEY ARE MOTOR CRAFT PLATINUM (CERAMIC INSIDE) SPARK PLUGS. NAPA SELLS A TOOL TO EXTRACT THE BROKE PLUG OUT. WHY IN THE WORLD THIS IS ALLOWED TO CONTINUE ON WITHOUT A RECALL IS BEYOND ME. FORD KNOWS ABOUT THESE ISSUES AND SHOULD HAVE A MASSIVE RECALL FOR THE ANY VEHICLE THAT CONTAINS THESE SPARK PLUGS, LIKE MY 2006 MODEL WITH A 5.3L DOES. I HAVE CALLED FORD AND FILED A FORMER COMPLAINT AND MANY OTHERS NEED TO DO SO AS WELL. I AM ALSO GOING TO FILE A COMPLAINT WITH THE BBB, AS I SPENT A HUGE CHUNK OF CHANGE AND PROPERLY MAINTAIN MY VEHICLE ON A DAILY BASIS. IF MY TRUCK HAS TO GO INTO A REPAIR SHOP TO HAVE THIS PLUG REMOVED, I WILL BE VERY DISAPPOINTED IN FORD'S CUSTOMER SERVICE. I HAVE 4 FORDS TODAY.......NOTHING HAS EVER BEEN THIS COSTLY! I HAVE A 71 BRONCO, 98 EXPLORER, 01 RANGER, AND 06 EXPEDITION. I GUESS THIS WILL DETERMINE IF I WILL STAY AS A FORD OWNER IN THE FUTURE. *TR

NHTSA ODI #10466460

77,000 miles · Jul 16, 2012
Latches/locks/linkages

TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT SOMEONE BROKE INTO THE VEHICLE AS A RESULT OF POORLY MANUFACTURED DOOR HANDLES. THE CONTACT STATED THAT THE DOORS WERE BROKEN INTO BY USING A SCREWDRIVER. THE VEHICLE WAS NOT TAKEN TO THE DEALER. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE WHO PROVIDED NO AS…

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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT SOMEONE BROKE INTO THE VEHICLE AS A RESULT OF POORLY MANUFACTURED DOOR HANDLES. THE CONTACT STATED THAT THE DOORS WERE BROKEN INTO BY USING A SCREWDRIVER. THE VEHICLE WAS NOT TAKEN TO THE DEALER. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE WHO PROVIDED NO ASSISTANCE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE AND CURRENT MILEAGE WAS 77,000.

NHTSA ODI #10465837

80,000 miles · Jul 16, 2012
Engine

TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 35 MPH, THE ENGINE STALLED WITH THE WARNING INDICATOR ILLUMINATED ON THE INSTRUMENT PANEL. THE VEHICLE WAS COASTED TO THE SIDE OF THE ROAD AND THE ENGINE TURNED OFF. THE VEHICLE RESTARTED AND RESUMED NORMALLY. THE VEHICLE HAD NOT BEE…

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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 35 MPH, THE ENGINE STALLED WITH THE WARNING INDICATOR ILLUMINATED ON THE INSTRUMENT PANEL. THE VEHICLE WAS COASTED TO THE SIDE OF THE ROAD AND THE ENGINE TURNED OFF. THE VEHICLE RESTARTED AND RESUMED NORMALLY. THE VEHICLE HAD NOT BEEN DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE PROBLEM. THE APPROXIMATE FAILURE MILEAGE WAS 80,000.

NHTSA ODI #10465762

102,000 miles · Jul 13, 2012
Engine

TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING 70 MPH THE VEHICLE STALLED AND THE FAIL SAFE MODE WARNING LIGHT ILLUMINATED. THE CONTACT WAS ABLE TO RESTART THE ENGINE AFTER SEVERAL MINUTES. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE DEALER WAS ALSO CONTACTED WHO ADVISED THE CONTACT T…

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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING 70 MPH THE VEHICLE STALLED AND THE FAIL SAFE MODE WARNING LIGHT ILLUMINATED. THE CONTACT WAS ABLE TO RESTART THE ENGINE AFTER SEVERAL MINUTES. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE DEALER WAS ALSO CONTACTED WHO ADVISED THE CONTACT THAT THE THROTTLE COULD HAVE FAILED. THE VEHICLE WAS NOT REPAIRED. THE FAILURE AND THE CURRENT MILEAGE WAS 102,000.

NHTSA ODI #10465518

79,000 miles · Jul 3, 2012
Engine

TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT WHILE THE BRAKES WERE DEPRESSED, THE ENGINE SAFE MODE WARNING LIGHT ILLUMINATED. THE VEHICLE WAS NOT TAKEN TO THE DEALER. THE MANUFACTURER WAS CONTACTED BUT THE VEHICLE WAS NOT REPAIRED. THE FAILURE AND CURRENT MILEAGES WERE 79,000.

NHTSA ODI #10464083

83,533 miles · May 2, 2012
Engine And Engine Cooling

I WAS ON HWY DOING 55 GETTING READY TO TAKE MY TURN OFF WHEN ENGINE SAFE MODE MESSAGE CAME ON. I THEN REALIZED THAT I HAD NO POWER EVEN THOUGH LIGHTS, RADIO, AND A/C WAS STILL ON. NOT BEING ABLE TO ACCELERATE I COASTED THE VEHICLE TO SIDE OF HWY AS FAR AS POSSIBLE, TURNED KEY TO OFF AND THAN BACK ON AND IT STARTED UP. I WAS AB…

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I WAS ON HWY DOING 55 GETTING READY TO TAKE MY TURN OFF WHEN ENGINE SAFE MODE MESSAGE CAME ON. I THEN REALIZED THAT I HAD NO POWER EVEN THOUGH LIGHTS, RADIO, AND A/C WAS STILL ON. NOT BEING ABLE TO ACCELERATE I COASTED THE VEHICLE TO SIDE OF HWY AS FAR AS POSSIBLE, TURNED KEY TO OFF AND THAN BACK ON AND IT STARTED UP. I WAS ABLE TO GET HOME WITHOUT FURTHER PROBLEM AND BACK TO WORK. UNFORTUNATELY I HAVE A 45 MINUTE DRIVE EVERY NIGHT AND EARLY MORNING TO AND FROM MY WORK WHICH IT COULD HAPPEN AGAIN AND NOT HAVE SUCH A GOOD CIRCUMSTANCE. THERE HAVE BEEN SEVERAL COMPLAINTS OVER SEVERAL YEARS TO FORD ON THIS WHY HAS IT NOT BEEN RECALLED? *JS

NHTSA ODI #10457105

109,000 miles · Apr 30, 2012
Engine And Engine Cooling

TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING 55 MPH, THE VEHICLE STALLED IN THE MIDDLE OF THE ROAD. THE VEHICLE WAS SAFELY MERGED ONTO THE SHOULDER AND THE CONTACT TURNED THE ENGINE OFF. THE CHECK ENGINE LIGHT ILLUMINATED PRIOR TO THE FAILURE. THE VEHICLE WAS TAKEN TO THE DEALER, WHO REPLACE…

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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING 55 MPH, THE VEHICLE STALLED IN THE MIDDLE OF THE ROAD. THE VEHICLE WAS SAFELY MERGED ONTO THE SHOULDER AND THE CONTACT TURNED THE ENGINE OFF. THE CHECK ENGINE LIGHT ILLUMINATED PRIOR TO THE FAILURE. THE VEHICLE WAS TAKEN TO THE DEALER, WHO REPLACED THE OXYGEN SENSOR, SPARKS PLUGS, AND ENGINE COILS. THE FAILURE CONTINUED. THE VEHICLE WAS TAKEN BACK TO THE DEALER AND THE CATALYTIC CONVERTER WAS REPLACED. THE FAILURE CONTINUED. THE CONTACT PLANNED ON TAKING THE VEHICLE BACK TO THE DEALER. THE MANUFACTURER WAS NOTIFIED AND STATED THAT THERE WERE NO RECALLS ADDRESSING THE FAILURE. NO FURTHER ASSISTANCE WAS OFFERED. THE FAILURE MILEAGE WAS 109,000.

NHTSA ODI #10456870

84,600 miles · Apr 28, 2012
Fuel System, Gasoline

MY CUSTOMER CALLED TO INFORM ME THAT HE WAS SMELLING RAW FUEL INSIDE THE VEHICLE ON APRIL 13,2012. I TOLD HIM IT WAS PROBABLY A STUCK INJECTOR. BEING A FORD SENIOR MASTER CERTIFIED AUTO REPAIR TECHNICIAN/ASE MASTER CERTIFIED FOR FORD DEALERSHIPS FOR OVER 14 YEARS I WAS AWARE OF THE INJECTOR CONCERNS WITH THESE VEHICLES. I CHECKE…

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MY CUSTOMER CALLED TO INFORM ME THAT HE WAS SMELLING RAW FUEL INSIDE THE VEHICLE ON APRIL 13,2012. I TOLD HIM IT WAS PROBABLY A STUCK INJECTOR. BEING A FORD SENIOR MASTER CERTIFIED AUTO REPAIR TECHNICIAN/ASE MASTER CERTIFIED FOR FORD DEALERSHIPS FOR OVER 14 YEARS I WAS AWARE OF THE INJECTOR CONCERNS WITH THESE VEHICLES. I CHECKED THE ENGINE OIL TO FIND THAT IT WAS OVERFILLED A QUART AND SMELLED OF FUEL. MY DIAGNOSIS WAS CORRECT #2 INJECTOR WAS LEAKING BADLY. I REPLACED #2 INJECTOR AND CHANGED THE OIL,FOUND SMALL SHARDS OF RUST IN THE INJECTOR THAT COULD ONLY HAVE COME FROM THE FUEL RAIL AS THEY WERE TOO LARGE TO HAVE BY-PASSED THE FUEL FILTER. 2005 F SERIESEXPEDITIONS/NAVIGATORS HAD A RECALL ON INJECTORS AND THE 2006-2007 VEHICLES SHOULD HAVE HAD THE RECALL. THIS COULD BE A POTENTIAL FIRE HAZZARD CAUSING MAJOR ENGINE DAMAGE IF IT OCCURS AGAIN.RESEARCH ONLINE AND FOUND THAT THOUSANDS OF FORD EXPEDITION,LICOLN NAVIGATOR AND F-150-250 OWNERS HAVE HAD THE SAME PROBLEMS WITH INJECTORS. I AM ALSO AWARE OF A RECALL THAT WAS ON CERTAIN EXPEDITIONS AND NAVIGATORS FOR A NEW FUEL RAIL THAT WAS RUSTING INTERNALLY CAUSING THE SAME PROBLEMS BUT THE RECALL JUST CLAIMS THAT THE FUEL RAILS WERE "DEFECTIVE".FORD MOTOR COMPANY IS AWARE OF THESE CONCERNS AND REFUSES TO RESOLVE OR HELP ANY OWNERS OF THE AFFECTED VEHICLES OUTSIDE THE RECALL. IF THESE VEHICLES ARE ALLOWED TO CONTINUE TO OPERATE WITHOUT BEING PROPERLY REPAIRED EVENTUALLY SOMEONE IS GOING TO BE INJURED OR WORSE. I HAVE WITNESSED ENGINE EXPLOSIONS AND FIRES CAUSED BY LEAKING INJECTORS. THIS IS CLEARLY A MANUFACTURE DEFECT AND SHOULD BE ADRESSED BY FORD MOTOR COMPANY.I URGE ANY FORD OWNERS WITH THIS PROBLEM TO FILE A CLAIM WITH NHTSA AS WELL AS FORD MOTOR COMPANY SO THEY CAN RESOLVE THESE CONCERN BEFORE ANYONE IS HARMED.ALL MY CUSTOMER WANTS IS THE FUEL RAIL AND INJECTORS REPLACED. *TR

NHTSA ODI #10456764

Mileage unknown · Apr 25, 2012
Engine And Engine Cooling

TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT WAS DRIVING 55 TO 65 MPH WHEN THE ENGINE SAFE MODE WARNING LIGHT ILLUMINATED AND THE ENGINE STALLED. THE VEHICLE RESTARTED AFTER THE FAILURE. THE FAILURE OCCURRED SEVEN DIFFERENT TIMES. THE VEHICLE WAS TAKEN TO THE DEALER. THE MANUFACTURER WAS ALSO NOTIFIED. THE VEHICLE WA…

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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT WAS DRIVING 55 TO 65 MPH WHEN THE ENGINE SAFE MODE WARNING LIGHT ILLUMINATED AND THE ENGINE STALLED. THE VEHICLE RESTARTED AFTER THE FAILURE. THE FAILURE OCCURRED SEVEN DIFFERENT TIMES. THE VEHICLE WAS TAKEN TO THE DEALER. THE MANUFACTURER WAS ALSO NOTIFIED. THE VEHICLE WAS NOT REPAIRED AND THE VIN WAS UNKNOWN. THE FAILURE AND CURRENT MILEAGES WERE UNKNOWN.

NHTSA ODI #10456443

10,756 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

Official recalls

2

05V520000 · Visibility:windshield Wiper/washer:motor

Nov 9, 2005

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.

05V310000 · Tires:tread/belt

Jul 6, 2005

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