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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
80,000 miles · Jun 28, 2010
Vehicle Speed Control

TL* CONTACT OWNS A 2005 FORD EXPEDITION. THE CONTACT STATED WHILE DRIVING AT 50 MPH, THE VEHICLE SUDDENLY STALLED WITHOUT WARNING. THE CONTACT WAS ABLE TO RESTART THE VEHICLE BUT IT STALLED A SECOND TIME WITHIN SECONDS. THE VEHICLE WAS TOWED TO HIS RESIDENCE. THE CONTACT WAS ABLE TO LOCATE NUMEROUS COMPLAINTS REGARDING THE THRO…

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TL* CONTACT OWNS A 2005 FORD EXPEDITION. THE CONTACT STATED WHILE DRIVING AT 50 MPH, THE VEHICLE SUDDENLY STALLED WITHOUT WARNING. THE CONTACT WAS ABLE TO RESTART THE VEHICLE BUT IT STALLED A SECOND TIME WITHIN SECONDS. THE VEHICLE WAS TOWED TO HIS RESIDENCE. THE CONTACT WAS ABLE TO LOCATE NUMEROUS COMPLAINTS REGARDING THE THROTTLE CONTROL AND BELIEVED IT TO BE THE CAUSE OF THE FAILURE. THE VEHICLE WAS NOT TAKEN TO THE DEALER FOR DIAGNOSTIC TESTING OR REPAIRS. THE FAILURE MILEAGE WAS 80,000.

NHTSA ODI #10340416

41,480 miles · Jun 24, 2010
Electrical SystemEngine And Engine Cooling

MY WIFE, THREE KIDS AND MYSELF WERE IN OUR 2006 FORD EXPEDITION LIMITED COMING DOWN A MOUNTAIN PASS IN LAKE TAHOE WHEN ALL OF A SUDDEN THE ENGINE STOPPED! A CODE ON THE DASH READ "FAIL SAFE ENGINE MODE". THE STEERING WHEEL LOCKED AND THERE WAS NO POWER, NO ACCELERATION. I WAS LUCKY TO PULL TO THE SIDE OF THE ROAD. THE FOLLOW…

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MY WIFE, THREE KIDS AND MYSELF WERE IN OUR 2006 FORD EXPEDITION LIMITED COMING DOWN A MOUNTAIN PASS IN LAKE TAHOE WHEN ALL OF A SUDDEN THE ENGINE STOPPED! A CODE ON THE DASH READ "FAIL SAFE ENGINE MODE". THE STEERING WHEEL LOCKED AND THERE WAS NO POWER, NO ACCELERATION. I WAS LUCKY TO PULL TO THE SIDE OF THE ROAD. THE FOLLOWING DAY, I TOOK THE TRUCK TO THE CARSON CITY, NV FORD DEALER AND PAID FOR A DIAGNOSTIC. NOTES FROM DEALER: ROAD TEST COULD NOT VERIFY. PERFORMED EEC SELF TEST, HAS CODE P0104. PERFORMED WIGGLE TEST AND PINPOINT TESTS. PERFORMED RECORDER-MONITOR TEST ALL THE PIDS LOOKED GOOD. REMOVED THE MAF SENSOR. HAS DEBRIS ON THE MAF SENSOR WIRES. RECOMMEND A NEW MAF SENSOR." I PUT IN A NEW MAF SENSOR AND AIR FILTER. IN DRIVING LESS THAN 3 MILES AFTER THIS WAS DONE, THE TRUCK DID THE SAME THING. THE "FAIL SAFE ENGINE MODE" CAME ON, LOSS OF POWER AND ACCELERATION. I HAD TO TURN THE TRUCK OFF COMPLETELY, REMOVE KEY AND RESTART. THEN THE TRUCK DID NOT HOLD THE IDLE AND DIED. AFTER A SECOND TIME, THE TRUCK RESTARTED. I AM STILL DRIVING WITH THE CHECK ENGINE LIGHT OFF AND HAVE ANOTHER APPOINTMENT WITH THE FORD DEALER TOMORROW MORNING (6-24-10) TO SEE WHAT IS GOING ON. WE ARE SUPPOSED TO LEAVE TOMORROW AND DRIVE 1100 MILES TO RETURN TO DENVER. *TR

NHTSA ODI #10339814

65,000 miles · Jun 15, 2010
Engine And Engine CoolingFuel System, Gasoline

TL*THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING THE CHECK ENGINE LIGHT ILLUMINATED. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALERSHIP WHERE THE CONTACT WAS INFORMED THAT THE FUEL INJECTORS WERE STUCK OPEN AND FLOODED THE ENGINE. THE DEALER ALSO STATED THAT BOTH CATALYTIC CONVERTERS WERE RUINED A…

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TL*THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING THE CHECK ENGINE LIGHT ILLUMINATED. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALERSHIP WHERE THE CONTACT WAS INFORMED THAT THE FUEL INJECTORS WERE STUCK OPEN AND FLOODED THE ENGINE. THE DEALER ALSO STATED THAT BOTH CATALYTIC CONVERTERS WERE RUINED AND NEEDED TO BE REPLACED, AND THE ENGINE WAS POSSIBLY DAMAGED. THE CONTACT STATED THAT THERE WAS A RECALL RELATED TO THE FAILURE FOR PREVIOUS MODEL YEARS AND WARRANTIES WERE EXTENDED AS A RESULT. THE CONTACT CALLED THE MANUFACTURER WHO STATED THAT THEY WOULD NOT EXTEND THE WARRANTY ON THE VEHICLE. THE CONTACT FILED A COMPLAINT. THE CURRENT AND FAILURE MILEAGES WERE APPROXIMATELY 65,000. UPDATED 11/19/10. *LJ UPDATED 10/27/10. *LJ THE CONSUMER STATED A NEW ENGINE WAS PUT IN THE VEHICLE. HOWEVER, HE CONTINUED TO EXPERIENCE PROBLEMS. THE DEALER STATED THE #6 CYLINDER HAD COMPRESSED CAUSING THE PISTON TO STOP A HALF INCH FROM THE TOP WHICH CAUSED THE VEHICLE TO SHUT DOWN. UPDATED 11/24/10

NHTSA ODI #10336418

40,000 miles · Jun 7, 2010
Engine And Engine Cooling

ON 2 SEPARATE OCCASIONS (BOTH AROUND 40,000 MILES), THE CAR JUST SHUT ITSELF OFF, WITHOUT WARNING, WHILE DRIVING DOWN THE ROAD AT ABOUT 40 MPH. POWER STEERING AND POWER BRAKING BOTH FAILED. I WAS JUST ABLE TO COAST ACROSS SEVERAL BUSY LANES OF TRAFFIC TO GET TO THE SIDE OF THE ROAD. THIS COULD BE EXTREMELY DANGEROUS, PARTIC…

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ON 2 SEPARATE OCCASIONS (BOTH AROUND 40,000 MILES), THE CAR JUST SHUT ITSELF OFF, WITHOUT WARNING, WHILE DRIVING DOWN THE ROAD AT ABOUT 40 MPH. POWER STEERING AND POWER BRAKING BOTH FAILED. I WAS JUST ABLE TO COAST ACROSS SEVERAL BUSY LANES OF TRAFFIC TO GET TO THE SIDE OF THE ROAD. THIS COULD BE EXTREMELY DANGEROUS, PARTICULARLY IF I WAS ON A FREEWAY OR INTERSTATE. THE DEALER'S DIAGNOSIS WAS THAT THE THROTTLE HAD GOTTEN STUCK WIDE OPEN, AND THAT THE CAR HAD TO GO INTO FAILSAFE MODE TO PREVENT IT FROM ACCELERATING OUT OF CONTROL. WHAT IF THE FAILSAFE MODE FAILS? I'VE READ NUMEROUS OTHER COMPLAINTS OF THE SAME THING HAPPENING ON OTHER 2006 FORD EXPEDITIONS. THERE IS CLEARLY A DEFECTIVE PART HERE, AND IT IS CLEARLY A SAFETY ISSUE. *TR

NHTSA ODI #10335094

99,000 miles · May 20, 2010
Engine And Engine Cooling

2006 FORD EXPEDITION SHUTS DOWN WHILE DRIVING ENGINE GOES INTO FAIL SAFE MODE WHICH IS LIKE NEUTRAL WITH LIMITED STEERING CAPABILITIES AND NO GAS PEDAL USE. BOUGHT VEHICLE IN DEC 09. THIS VEHICLE HAS DONE THIS APPROX 7 TIMES. HAS HAPPENED WHILE ON SURFACE STREETS AS WELL AS THE FREEWAY. VERY DANGEROUS. AT DEALER FOR THIRD TIME …

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2006 FORD EXPEDITION SHUTS DOWN WHILE DRIVING ENGINE GOES INTO FAIL SAFE MODE WHICH IS LIKE NEUTRAL WITH LIMITED STEERING CAPABILITIES AND NO GAS PEDAL USE. BOUGHT VEHICLE IN DEC 09. THIS VEHICLE HAS DONE THIS APPROX 7 TIMES. HAS HAPPENED WHILE ON SURFACE STREETS AS WELL AS THE FREEWAY. VERY DANGEROUS. AT DEALER FOR THIRD TIME AND THEY ARE GIVING A THIRD REASON FOR IT HAPPENING. CHECKED INTERNET AND IT IS FULL OF COMPLAINTS OF EXACTLY SAME PROBLEM WITH NO RESOLUTION FROM ANY MECHANICS BUT SEVERAL DIFFERENT REASONS THEY WERE GIVEN. A DEFINITE SAFETY ISSUE! ON THE PHONE WITH FORD CUSTOMER SERVICE TODAY ABOUT THE ISSUE. THEY WILL GET BACK TO ME TOMORROW. NO RECALLS ON THIS, APPARENTLY UNTIL SOMEONE GETS HURT. THIS IS ANOTHER TOYOTA ISSUE WAITING TO HAPPEN. I AM A STATE TROOPER AND YOU CAN BELIEVE I FEEL THIS IS SERIOUS AND NEEDS TO BE ADDRESSED. SOMEONE COULD BE SERIOUSLY HURT OR KILLED ESPECIALLY ON THE FREEWAY WHEN THIS HAPPENS. *TR

NHTSA ODI #10331400

111,000 miles · May 14, 2010
Fuel System, Gasoline

ENGINE SAFE FAIL MODE CAME ON WHILE DRIVING MY 2006 FORD EXPEDITION WHICH ALSO LEAD TO THE VEHICLE SHUTTING DOWN IN THE MIDDLE OF THE HIGHWAY. THE NEXT READING THAT WAS CONNECTED TO THIS WARNING WAS...ENGINE OFF...LOW FUEL OIL PRESSURE. I CHECKED UNDER THE HOOD OF THE VEHICLE TO SEE IF THERE WAS ANY OIL LEAKS OR IF THE READING…

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ENGINE SAFE FAIL MODE CAME ON WHILE DRIVING MY 2006 FORD EXPEDITION WHICH ALSO LEAD TO THE VEHICLE SHUTTING DOWN IN THE MIDDLE OF THE HIGHWAY. THE NEXT READING THAT WAS CONNECTED TO THIS WARNING WAS...ENGINE OFF...LOW FUEL OIL PRESSURE. I CHECKED UNDER THE HOOD OF THE VEHICLE TO SEE IF THERE WAS ANY OIL LEAKS OR IF THE READING WAS REALLY LOW AND ALL SEEN FINE. THIS IS A VERY SCARY INCIDENT BECAUSE THE VEHICLE JUST SHUTS DOWN IN THE MIDDLE OF TRASH WHICH COULD CAUSE AN ACCIDENT MAYBE FATAL. *TR

NHTSA ODI #10330441

76,000 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…

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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 …

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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

59,755 miles · Apr 28, 2010
Structure

I HAVE A 2006 FORD EXPEDITION EDDIE BAUER UNDER 5 YEARS OLD THAT THE TAILGATE IS SEVERELY BLISTERED ALL OVER, PAINT HAS EVEN POPPED OFF OF IT. THERE IS ALSO SOME ON THE HOOD. THE LOCAL FORD DEALERSHIP ADMITTED THAT FORD HAD A PROBLEM WITH THE BLISTERING PAINT AND TOLD ME HOW BAD MY VEHICLE WAS. THEY TOOK PICTURES AND SENT TO FOR…

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I HAVE A 2006 FORD EXPEDITION EDDIE BAUER UNDER 5 YEARS OLD THAT THE TAILGATE IS SEVERELY BLISTERED ALL OVER, PAINT HAS EVEN POPPED OFF OF IT. THERE IS ALSO SOME ON THE HOOD. THE LOCAL FORD DEALERSHIP ADMITTED THAT FORD HAD A PROBLEM WITH THE BLISTERING PAINT AND TOLD ME HOW BAD MY VEHICLE WAS. THEY TOOK PICTURES AND SENT TO FORD. FORD REP DENIED IT AND I WAS TOLD THAT EVEN IF HOLES APPEARED AS A RESULT NOW THEY WOULD DO NOTHING FOR ME BECAUSE THEY HAD ALREADY DENIED AND ONLY LOOK AT A CLAIM FOR ONE THING ONE TIME. I PURSUED FURTHER BY CALLING CUSTOMER SERVICE AND EMAILING THEM AS WELL. THE CUSTOMER SERVICE REP ALSO ADMITTED THERE WAS A PROBLEM WITH PAINT BLISTER BUT COULD DO NOTHING FOR ME BECAUSE IT HAD ALREADY BEEN DENIED. I HAVE OWNED FORDS ALL OF MY LIFE AND EVEN WORKED FOR A LINCOLN MERCURY DEALERSHIP FOR SEVERAL YEARS. I AM CONTINUING TO PURSUE THIS AS FAR AS I CAN AND ASK FOR ANY HELP THAT CAN BE OFFERED IN THIS MATTER. *TR

NHTSA ODI #10327913

120,000 miles · Apr 19, 2010
Wheels

2006 FORD EXPEDITION (LAW ENFORCEMENT PACKAGE) WITH STEEL WHEELS AND APPROX. 120,000 MILES; WHEEL SEPARATION (CRACKED ALONG WELD). PRIOR TO THE FAILURE, THIS VEHICLE WAS USED DAILY FOR ROUTINE LAW ENFORCEMENT PATROL DUTIES. WE HAVE HAD THIS ISSUE ON SEVERAL 2006 EXPEDITIONS. UPON LEARNING OF THE POTENTIAL FOR THE WHEEL FAILUR…

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2006 FORD EXPEDITION (LAW ENFORCEMENT PACKAGE) WITH STEEL WHEELS AND APPROX. 120,000 MILES; WHEEL SEPARATION (CRACKED ALONG WELD). PRIOR TO THE FAILURE, THIS VEHICLE WAS USED DAILY FOR ROUTINE LAW ENFORCEMENT PATROL DUTIES. WE HAVE HAD THIS ISSUE ON SEVERAL 2006 EXPEDITIONS. UPON LEARNING OF THE POTENTIAL FOR THE WHEEL FAILURE, WE HAVE IMPLEMENTED PROCEDURES TO INSPECT THE WHEELS FOR CRACKS AND OTHER DAMAGE REGULARLY. IN ALL CASES, THERE HAVE BEEN NO OBVIOUS WARNING SIGNS BEFORE FAILURE. THIS PROBLEM WAS DISCOVERED WHEN THE OFFICER NOTICED A FLAT TIRE PRIOR TO STARTING HIS SHIFT FOR THE DAY. UPON FINDING THE CRACKED WHEEL A NEW REPLACEMENT WHEEL WAS INSTALLED ON THE VEHICLE. *TR

NHTSA ODI #10326438

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