NHTSA owner reports · September 18, 2026 snapshot.
What owners actually said
299 reports103,000 miles · Feb 28, 2012
Vehicle Speed Control
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT THE VEHICLE DECELERATED AND ENTERED INTO FAIL SAFE MODE WHILE DRIVING 55 MPH. THE VEHICLE WOULD NOT ACCELERATE FURTHER ONCE IT ENTERED FAIL SAFE MODE. THE CONTACT SHUT THE VEHICLE OFF AND UPON RESTART, THE VEHICLE OPERATED AS NORMAL. THE FAILURE RECURRED ONCE. …
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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT THE VEHICLE DECELERATED AND ENTERED INTO FAIL SAFE MODE WHILE DRIVING 55 MPH. THE VEHICLE WOULD NOT ACCELERATE FURTHER ONCE IT ENTERED FAIL SAFE MODE. THE CONTACT SHUT THE VEHICLE OFF AND UPON RESTART, THE VEHICLE OPERATED AS NORMAL. THE FAILURE RECURRED ONCE. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER AND THE CONTACT WAS INFORMED THAT THE THROTTLE BODY NEEDED TO BE REPLACED. THE VEHICLE WAS IN THE PROCESS OF BEING REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE, BUT OFFERED NO ASSISTANCE. THE FAILURE MILEAGE WAS 103,000. UPDATED 8/23/12 *CN UPDATED 09/06/2012 *JS
NHTSA ODI #10449526
83,000 miles · Feb 14, 2012
Electrical System
I HAVE THIS PROBLEM WHERE MY TRUCK IS LOSING POWER AND THEN DYING WHILE I AM DRIVING. THIS IS VERY DANGEROUS ON THE ROADWAYS. I HAVE A SPECIAL NEEDS CHILD AND GRAND CHILDREN THAT I TRANSPORT. FORD NEEDS TO RECALL THESE TRUCKS AND FIX THEM. *TR
NHTSA ODI #10447969
82,000 miles · Feb 13, 2012
Engine And Engine Cooling
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT THE VEHICLE STALLED WHILE DRIVING AT VARIOUS SPEEDS AND THE ENGINE SAFE MODE WARNING INDICATOR ILLUMINATED. THE CONTACT STATED THAT THE FAILURE OCCURRED ON THREE PRIOR OCCASIONS. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER, WHO WAS UNABLE TO DIAGNOSE THE FAIL…
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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT THE VEHICLE STALLED WHILE DRIVING AT VARIOUS SPEEDS AND THE ENGINE SAFE MODE WARNING INDICATOR ILLUMINATED. THE CONTACT STATED THAT THE FAILURE OCCURRED ON THREE PRIOR OCCASIONS. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER, WHO WAS UNABLE TO DIAGNOSE THE FAILURE. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE, BUT OFFERED NO ASSISTANCE AND REFERRED THE CONTACT TO NHTSA. THE VEHICLE WAS NOT REPAIRED. THE FAILURE AND CURRENT MILEAGES WERE 82,000.
NHTSA ODI #10447835
55,000 miles · Feb 11, 2012
Engine And Engine Cooling
ENGINE FAIL SAFE MODE RESULTING IN COMPLETE SHUTDOWN WHILE GOING AT HIGHWAY SPEED. VEHICLE LOSSES ALL POWER AND HAS TO BE RESTARTED. *TR
NHTSA ODI #10447516
88,000 miles · Feb 6, 2012
Vehicle Speed Control
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT THE VEHICLE STALLED NUMEROUS TIMES WITH THE ILLUMINATION OF THE CHECK ENGINE LIGHT AFTER THE FAILURE OCCURRED. THE VEHICLE WAS TAKEN TO THE DEALER AND A DIAGNOSTIC WAS PERFORMED, WHICH LOCATED THE FAILURE AT THE THROTTLE BODY. THE VEHICLE WAS NOT REPAIRED. THE …
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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT THE VEHICLE STALLED NUMEROUS TIMES WITH THE ILLUMINATION OF THE CHECK ENGINE LIGHT AFTER THE FAILURE OCCURRED. THE VEHICLE WAS TAKEN TO THE DEALER AND A DIAGNOSTIC WAS PERFORMED, WHICH LOCATED THE FAILURE AT THE THROTTLE BODY. THE VEHICLE WAS NOT REPAIRED. THE FAILURE AND THE CURRENT MILEAGE WAS 88,000.
NHTSA ODI #10446900
90,000 miles · Feb 6, 2012
Engine And Engine CoolingFire
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT THE VEHICLE WOULD ONLY SHIFT INTO REVERSE. UPON EXAMINING THE VEHICLE, THE CONTACT NOTICED THAT A WIRING HARNESS WITHIN THE ENGINE MELTED AGAINST THE EXHAUST MANIFOLD. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER AND THE CONTACT WAS INFORMED THAT THE WIRING HA…
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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT THE VEHICLE WOULD ONLY SHIFT INTO REVERSE. UPON EXAMINING THE VEHICLE, THE CONTACT NOTICED THAT A WIRING HARNESS WITHIN THE ENGINE MELTED AGAINST THE EXHAUST MANIFOLD. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER AND THE CONTACT WAS INFORMED THAT THE WIRING HARNESS NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND OFFERED NO ASSISTANCE. THE FAILURE MILEAGE WAS 90,000.
NHTSA ODI #10446777
85,000 miles · Jan 23, 2012
Tires
WHILE INFLATING TIRES DURING A SERVICE THE CUSTOMER'S VALVE STEM BROKE. *TR
NHTSA ODI #10444963
40,000 miles · Jan 19, 2012
Engine And Engine Cooling
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. WHILE DRIVING APPROXIMATELY 25 MPH, THE VEHICLE STALLED WITHOUT WARNING. THE FAILURE RECURRED SPORADICALLY AND AT DIFFERENT SPEEDS. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC FOR DIAGNOSTICS. THE CONTACT WAS NOT AWARE OF THE REPAIRS NEEDED. THE VEHICLE WAS NOT REPAIRED. THE VIN…
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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. WHILE DRIVING APPROXIMATELY 25 MPH, THE VEHICLE STALLED WITHOUT WARNING. THE FAILURE RECURRED SPORADICALLY AND AT DIFFERENT SPEEDS. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC FOR DIAGNOSTICS. THE CONTACT WAS NOT AWARE OF THE REPAIRS NEEDED. THE VEHICLE WAS NOT REPAIRED. THE VIN WAS NOT AVAILABLE. THE APPROXIMATE FAILURE MILEAGE WAS 40,000.
NHTSA ODI #10444512
160,000 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
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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