NHTSA owner reports · September 18, 2026 snapshot.
What owners actually said
299 reports98,900 miles · Feb 3, 2011
Engine And Engine CoolingInjury
I WAS PREPARING TO MAKE A LEFT HAND TURN INTO A BUSY OFFICE COMPLEX, AND THE ENGINE IN MY 2006 FORD EXPEDITION CUT OFF. THE SYSTEM GENERATED CODE WAS 'ENGINE FAILSAFE MODE". I TURNED ON MY HAZARDS, PUT THE CAR IN PARK AND WAITED A FEW MINUTES TO RESTART. THE ENGINE CAR STARTED, BUT THE FACT THAT IT CUT OFF, WITHOUT WARNING IS…
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I WAS PREPARING TO MAKE A LEFT HAND TURN INTO A BUSY OFFICE COMPLEX, AND THE ENGINE IN MY 2006 FORD EXPEDITION CUT OFF. THE SYSTEM GENERATED CODE WAS 'ENGINE FAILSAFE MODE". I TURNED ON MY HAZARDS, PUT THE CAR IN PARK AND WAITED A FEW MINUTES TO RESTART. THE ENGINE CAR STARTED, BUT THE FACT THAT IT CUT OFF, WITHOUT WARNING IS EXTREMELY ALARMING. I'VE CONTACTED FORD CORPORATE WHO SAID THAT THERE WERE NO RECALLS, AND THAT I NEEDED TO GO TO A SERVICE CENTER. AFTER RESEARCHING THE INTERNET AND THIS SITE, I AM CONVINCED THAT THIS ISSUE SHOULD PROMPT A RECALL, BUT FORD'S COST-BENEFIT ANALYSIS INDICATES THAT IT IS WAITING UNTIL THERE ARE ENOUGH FATALITIES TO MAKE THE DETERMINATION TO FIX WHAT APPEARS TO BE A $600-800 ISSUE. FORD SHOULD BE AND CAN BE HELD LIABLE FOR GROSS NEGLIGENCE IN THEIR DELIBERATE DECISION TO DISREGARD THE ENGINE FAILURE COMPLAINTS. I HAVE BEEN A LOYAL FORD CUSTOMER FOR SEVERAL DECADES. THAT IS NO LONGER THE CASE. *TR
NHTSA ODI #10380086
45,000 miles · Jan 16, 2011
Unknown Or Other
'06 EXPEDITION WENT INTO ENGINE FAIL SAFE MODE AS MY WIFE WAS ATTEMPTING TO MAKE A LEFT HAND TURN CROSSING 2 LANES OF TRAFFIC AT A BUSY INTERSECTION. AFTER COASTING INTO A PARKING LOT, SHE TURNED IT OFF AND TURNED IT BACK ON. IT STARTED RIGHT UP AND SHE WENT ON HER WAY. TOOK IT TO A MECHANIC WHO SAID HE COULD FIND NOTHING WRONG.…
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'06 EXPEDITION WENT INTO ENGINE FAIL SAFE MODE AS MY WIFE WAS ATTEMPTING TO MAKE A LEFT HAND TURN CROSSING 2 LANES OF TRAFFIC AT A BUSY INTERSECTION. AFTER COASTING INTO A PARKING LOT, SHE TURNED IT OFF AND TURNED IT BACK ON. IT STARTED RIGHT UP AND SHE WENT ON HER WAY. TOOK IT TO A MECHANIC WHO SAID HE COULD FIND NOTHING WRONG. UPON FURTHER INVESTIGATION, I HAVE FOUND 100'S OF '06 EXPEDITIONS WITH THE SAME PROBLEM AND IT SEEMS TO POINT TO THE THROTTLE BODY. A RECENT AC REPAIR TO THIS CAR WAS ALMOST $800.00 AND NOW I AM HEARING TO REPAIR THE THROTTLE BODY IS UPWARD TO $700-$800. $1500 OF REPAIRS ON A CAR WITH ONLY 45,000 MILES IS UNACCEPTABLE. THE THROTTLE BODY PROBLEM IS VERY DANGEROUS AND FORD SHOULD RECALL THESE CARS AND FIND OUT WHY THIS IS HAPPENING BEFORE SOMEONE GETS HURT OR EVEN WORSE, KILLED. *LN
NHTSA ODI #10376844
Mileage unknown · Jan 13, 2011
Air BagsCrashInjury
I WAS TRAVELING DOWN THE ROAD HIT BLACK ICE AND THEN SLIDE INTO A TREE HEAD ON. BOTH THE DRIVERSIDE AND PASSENGER SIDE AIRBAGS FAILED TO DEPLOY. I WAS WEARING MY SEAT BELT BUT STILL SUFFERED FACIAL TRAUMA. I RECEIVED SEVERAL SUTURES IN MY LIPS AND THE INSIDE OF MY MOUTH. I THINK FORD SHOULD INVESTIGATE AND DO SOMETHING ABOUT T…
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I WAS TRAVELING DOWN THE ROAD HIT BLACK ICE AND THEN SLIDE INTO A TREE HEAD ON. BOTH THE DRIVERSIDE AND PASSENGER SIDE AIRBAGS FAILED TO DEPLOY. I WAS WEARING MY SEAT BELT BUT STILL SUFFERED FACIAL TRAUMA. I RECEIVED SEVERAL SUTURES IN MY LIPS AND THE INSIDE OF MY MOUTH. I THINK FORD SHOULD INVESTIGATE AND DO SOMETHING ABOUT THIS PROBLEM. I FEEL THAT IF MY AIRBAGS WOULD HAVE DEPLOYED I WOULDN'T HAVE SUFFERED THE TRAUMA TO MY FACE. *TR
NHTSA ODI #10376575
59,000 miles · Jan 11, 2011
Electrical System
2006 FORD EXPEDITION SHUTS OFF WHILE DRIVING. EXTREMELY DANGEROUS. CAR WILL START BACK UP WITHOUT ANY PROBLEMS BUT WILL SHUT DOWN SPORADICALLY. *TR
NHTSA ODI #10376233
76,170 miles · Jan 6, 2011
Electrical SystemFuel System, Gasoline
MY WIFE WAS DRIVING HER 2006 FORD EXPEDITION DOWN A BUSY ROAD AT A SPEED OF ABOUT 40 MPH. SHE WAS DRIVING WITH ANOTHER FRIEND AND OUR 2 CHILDREN (18 MONTHS AND 1 WEEK!) A WRENCH SYMBOL WARNING LIGHT CAME ON AND THE VEHICLE SHUT DOWN. SHE PUT ON HER HAZARDS AND WAS ABLE TO SAFELY COME TO A STOP. SHE TURNED THE IGNITION KEY TO THE…
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MY WIFE WAS DRIVING HER 2006 FORD EXPEDITION DOWN A BUSY ROAD AT A SPEED OF ABOUT 40 MPH. SHE WAS DRIVING WITH ANOTHER FRIEND AND OUR 2 CHILDREN (18 MONTHS AND 1 WEEK!) A WRENCH SYMBOL WARNING LIGHT CAME ON AND THE VEHICLE SHUT DOWN. SHE PUT ON HER HAZARDS AND WAS ABLE TO SAFELY COME TO A STOP. SHE TURNED THE IGNITION KEY TO THE OFF POSITION AND THEN WAS ABLE TO START THE ENGINE AGAIN. AFTER TALKING TO A MECHANIC AND DOING INTERNET RESEARCH I FOUND THIS IS A VERY COMMON PROBLEM WHICH CONSISTS OF THE ELECTRONIC CONTROL OF THE THROTTLE. THE FIX IS UPWARDS OF $500; SO A RECALL OF SOMETHING THAT EXPENSIVE CAN EASILY BE BRUSHED UNDER THE TABLE BY FORD. THIS PROBLEM NEEDS TO BE ADDRESSED BY FORD. IF MORE VEHICLES KEEP SHUTTING DOWN ON THEIR OWN SOMEONE WILL SOON BE INJURED OR KILLED. *TR
NHTSA ODI #10374970
84,000 miles · Jan 4, 2011
Engine And Engine Cooling
I AM FILING A COMPLAINT DUE TO MY 2006 FORD EXPEDITION. OVER THE FEW YEARS THAT I HAVE OWNED THE S.U.V., FOR NO APPARENT REASON THE VEHICLE JUST QUITS RUNNING, ENTERS A FAIL SAFE MODE, AND ALL POWER IS LOST TO THE VEHICLE. THIS HAS HAPPENED NOW ON MANY OCCASIONS AND WITHOUT ANY WARNING. ITS HAPPENED ON INTERSTATES, BRIDGES, AS …
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I AM FILING A COMPLAINT DUE TO MY 2006 FORD EXPEDITION. OVER THE FEW YEARS THAT I HAVE OWNED THE S.U.V., FOR NO APPARENT REASON THE VEHICLE JUST QUITS RUNNING, ENTERS A FAIL SAFE MODE, AND ALL POWER IS LOST TO THE VEHICLE. THIS HAS HAPPENED NOW ON MANY OCCASIONS AND WITHOUT ANY WARNING. ITS HAPPENED ON INTERSTATES, BRIDGES, AS WELL AS CROSSING MULTIPLE LANED HIGHWAYS. THIS IS A TREMENDOUS SAFETY ISSUE THAT NEEDS TO BE ADDRESSED. AT FIRST I THOUGHT MY CASE MIGHT BE ISOLATED, BUT THEN AFTER SOME RESEARCH, I FOUND THAT THOUSANDS ARE HAVING THE SAME PROBLEM WITH THEIR EXPEDITION AS WELL. I FEEL FORD SHOULD FIND THE PROBLEM AND FIX IT BEFORE LIVES ARE DESTROYED. MY WIFE AND CHILDREN ARE IN THIS VEHICLE EVERYDAY. PLEASE IF THERE'S ANYTHING YOU CAN DO.....HELP US!! *TR
NHTSA ODI #10374056
80,000 miles · Dec 29, 2010
Unknown Or Other
2006 FORD EXPEDITION, "ENGINE FAIL SAFE MODE" CAR HAS SHUT OFF WHILE DRIVING 5 TIMES IN THE LAST 6 MONTHS. THE ONLY WAY TO GET THE CAR MOVING IS TO START IT AGAIN. EXTREMELY UNSAFE. THIS VEHICLE WAS COVERED UNDER AN EXTENDED WARRANTY AND HAS GONE IN FOR SERVICE TO CORRECT THE PROBLEM. FORD CANNOT IDENTIFY THE PROBLEM! COMES…
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2006 FORD EXPEDITION, "ENGINE FAIL SAFE MODE" CAR HAS SHUT OFF WHILE DRIVING 5 TIMES IN THE LAST 6 MONTHS. THE ONLY WAY TO GET THE CAR MOVING IS TO START IT AGAIN. EXTREMELY UNSAFE. THIS VEHICLE WAS COVERED UNDER AN EXTENDED WARRANTY AND HAS GONE IN FOR SERVICE TO CORRECT THE PROBLEM. FORD CANNOT IDENTIFY THE PROBLEM! COMES UP WITH "NO CODE". I'M NOW OFF WARRANTY AND STUCK WITH A VERY UNSAFE VEHICLE! FORD NEEDS TO ADDRESS THIS PROBLEM IMMEDIATELY! *TR
NHTSA ODI #10373209
93,500 miles · Dec 20, 2010
Engine And Engine Cooling
COMPLAINT FILED REGARDING A PERSONALLY OWNED 2006 FORD EXPEDITION XLT, OWNED FROM 2/2010 TO PRESENT (12/2010)> THREE SEPARATE INSTANCES WHEN DRIVING THE VEHICLE WHEN THE "FAILSAFE MODE" WARNING LIGHTS AND ALL LOSS OF VEHICLE CONTROL:STEERING, BRAKES, ACCELERATION, ETC. OCCURRED/ RANDOMLY DURING THIS PERIOD OF OWNERSHIP WITH NO A…
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COMPLAINT FILED REGARDING A PERSONALLY OWNED 2006 FORD EXPEDITION XLT, OWNED FROM 2/2010 TO PRESENT (12/2010)> THREE SEPARATE INSTANCES WHEN DRIVING THE VEHICLE WHEN THE "FAILSAFE MODE" WARNING LIGHTS AND ALL LOSS OF VEHICLE CONTROL:STEERING, BRAKES, ACCELERATION, ETC. OCCURRED/ RANDOMLY DURING THIS PERIOD OF OWNERSHIP WITH NO APPARENT REASON. VEHICLE RESTARTED IMMEDIATELY. ALL INSTANCES OF THE CONDITION OCCURRED WHEN OUTSIDE TEMPERATURE WAS BELOW FREEZING (WINTER MONTHS) INTO A RIGHT OR LEFT TURN. NO EVIDENCE OF LOSS OF ANTIFREEZE, ENGINE OVERHEATING, COOLANT LEAKS, ETC. MECHANIC ASSESSMENT COULD NOT FIND A REASON FOR THE ENGINE FAIL SAFE ACTIVATION. THIS IS A SIGNIFICANT, POTENTIAL SAFETY PROBLEM FOR THE DRIVER/PASSENGERS OF 2006 FORD EXPEDITIONS EXPERIENCING THE RANDOM OCCURRING ENGINE FAILURE ATTRIBUTABLE TO THE FAILSAFE FEATURE OF THIS VEHICLE. *TR
NHTSA ODI #10371851
38,500 miles · Oct 28, 2010
Air BagsCrashInjury
I WAS STOPPED AT A RED LIGHT, CONSTRUCTION TRUCK RAN INTO BACK OF MY 2006 FORD EXPEDITION. THE IMPACT PUSHED ME 20 FEET INTO THE VEHICLE IN FRONT OF ME, SANDWICHING MY VEHICLE IN BETWEEN THE OTHER TWO; THE IMPACT FIRST THREW ME BACK THEN FORWARD & SENT MY GLASSES OFF MY HEAD BUT THE AIRBAG DID NOT DEPLOY. I GOT A CONCUSSION & …
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I WAS STOPPED AT A RED LIGHT, CONSTRUCTION TRUCK RAN INTO BACK OF MY 2006 FORD EXPEDITION. THE IMPACT PUSHED ME 20 FEET INTO THE VEHICLE IN FRONT OF ME, SANDWICHING MY VEHICLE IN BETWEEN THE OTHER TWO; THE IMPACT FIRST THREW ME BACK THEN FORWARD & SENT MY GLASSES OFF MY HEAD BUT THE AIRBAG DID NOT DEPLOY. I GOT A CONCUSSION & SHOULDER INJURY DUE TO FORCE. POLICE & MEDICAL PERSONS WERE AMAZED THAT AIRBAG DID NOT DEPLOY. VEHICLE HAD FRONT END & REAR DAMAGE, WAS UNDRIVEABLE & HAD TO BE TOWED AWAY. I AM WAITING TO FIND OUT IF IT WILL BE TOTALED OUT.
NHTSA ODI #10363330
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
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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