NHTSA owner reports · September 18, 2026 snapshot.
Electrical System complaints
76 reportsClear category filter88,000 miles · Mar 2, 2013
Electrical SystemEngineService Brakes
WHILE DRIVING AT 40 MPH ENGINE STOPPED WORKING MAKING BRAKES AND STEERING FAIL. LIMPED OFF BUSY ROAD LUCKILY! ENGINE LIGHT SHOWED ELECTRONIC THROTTLE FAILURE. NOW CHECK ENGINE LIGHT IS ON. GOING TO DEALERS FOR REPAIR TODAY-SINCE THIS IS AN OBVIOUS PROBLEM FOR FORD WHY HAVEN'T THEY ADDRESSED IT! COULD BE DEADLY IF FAILS IN HEA…
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WHILE DRIVING AT 40 MPH ENGINE STOPPED WORKING MAKING BRAKES AND STEERING FAIL. LIMPED OFF BUSY ROAD LUCKILY! ENGINE LIGHT SHOWED ELECTRONIC THROTTLE FAILURE. NOW CHECK ENGINE LIGHT IS ON. GOING TO DEALERS FOR REPAIR TODAY-SINCE THIS IS AN OBVIOUS PROBLEM FOR FORD WHY HAVEN'T THEY ADDRESSED IT! COULD BE DEADLY IF FAILS IN HEAVY TRAFFIC CONDITIONS. *TR
NHTSA ODI #10501011
119,000 miles · Jan 25, 2013
Electrical SystemEngine And Engine Cooling
THE SPARK PLUG BROKE IN THE ENGINE COSTING A LOT OF MONEY TO REPAIR. NOW ANOTHER ONE IS STUCK AND I CANT AFFORD TO GET IT FIXED. THIS COULD POSSIBLY CAUSE FIRE AND CREATE A SAFETY HAZARD. THERE ARE NUMEROUS COMPLAINTS OUT THERE AND THIS REALLY NEEDS TO BE A RECALL SITUATION. *TR
NHTSA ODI #10494763
10,000 miles · Dec 1, 2012
Electrical SystemEnginePower Train
FIRST TIME IT OCCURRED I WAS TRAVELING TO WORK THE CAR STALLED WHILE DRIVING APPROX. 20 MPH AND THERE WAS NO CONTROL OF THE CAR - WAS ABLE TO MOVE TO SIDE OF ROAD AND RESTART. FAULT ON THE CONSOLE WAS "ELECTRONIC THROTTLE". HAS HAPPEN APPROX 4 MORE TIMES AT VARIOUS SPEEDS AND CONDITIONS WITH THREE DIFFERENT DRIVERS. NO PROBLE…
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FIRST TIME IT OCCURRED I WAS TRAVELING TO WORK THE CAR STALLED WHILE DRIVING APPROX. 20 MPH AND THERE WAS NO CONTROL OF THE CAR - WAS ABLE TO MOVE TO SIDE OF ROAD AND RESTART. FAULT ON THE CONSOLE WAS "ELECTRONIC THROTTLE". HAS HAPPEN APPROX 4 MORE TIMES AT VARIOUS SPEEDS AND CONDITIONS WITH THREE DIFFERENT DRIVERS. NO PROBLEM EVER FOUND BY DEALER. HAS HAPPENED AT HIGH SPEED ON THE FREEWAY COMPLETE LOSS OF STEERING AND POWER OCCURS MORE CONCERNING IT CAN HAPPEN AT ANY TIME WITHOUT WARNING. I FIND THIS TO BE EXTREMELY DANGEROUS AND A DEATH TRAP WAITING TO HAPPEN. THE LAST TIME IT OCCURRED WHEN BY TEENAGE DAUGHTER WAS DRIVING SHE WAS SCARED TO DEATH REFUSING TO DRIVE IT HOME. THIS REMINDED ME OF TOYOTA PRIUS SO I TOOK IT UPON MYSELF TO REPORT MY INCIDENTS. LOOKING AT THE INTERNET I NOW FIND IT OCCURS FREQUENTLY AND IT IS NOT AN ISOLATED CASE. *TR
NHTSA ODI #10486629
93,000 miles · Nov 12, 2012
Electrical System
MY 2005 EXPEDITION WAS TRAVELING AT A SPEED OF 40MPH WHEN IT STOPPED ACCELERATING AND DIED IN TRAFFIC WHILE I WAS TAKING MY KIDS TO SCHOOL. I COULDN'T TURN THE STIRRING WHEEL TO GET OFF OF THE ROAD. THIS IS A VERY DANGEROUS PROBLEM AND IT HAS HAPPENED TO ME ABOUT THREE OR FOUR TIMES. ONCE IT HAPPENED WHEN I WAS PULLING OUT IN…
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MY 2005 EXPEDITION WAS TRAVELING AT A SPEED OF 40MPH WHEN IT STOPPED ACCELERATING AND DIED IN TRAFFIC WHILE I WAS TAKING MY KIDS TO SCHOOL. I COULDN'T TURN THE STIRRING WHEEL TO GET OFF OF THE ROAD. THIS IS A VERY DANGEROUS PROBLEM AND IT HAS HAPPENED TO ME ABOUT THREE OR FOUR TIMES. ONCE IT HAPPENED WHEN I WAS PULLING OUT INTO TRAFFIC ON A HILL THANK GOD NO ONE ELSE WAS COMING. *TR
NHTSA ODI #10484008
71,000 miles · Jul 22, 2012
Electrical SystemExterior LightingStructure
THE AIR CONDITIONING UNIT IS LEAKING EXCESSIVE AMOUNTS OF WATER UNDER THE CARPET AND THE WATER IS POOLING UNDER THE RUG AND FLOWING INTO THE CHANNEL WHERE THE WIRING HARNESS IS LOCATED. THIS WIRING HARNESS DOES NOT LOOK TO BE PROTECTED FROM WATER AND IT IS A MATER OF TIME BEFORE THE INSULATION ON THIS WIRE BREAKS DOWN AND SHOR…
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THE AIR CONDITIONING UNIT IS LEAKING EXCESSIVE AMOUNTS OF WATER UNDER THE CARPET AND THE WATER IS POOLING UNDER THE RUG AND FLOWING INTO THE CHANNEL WHERE THE WIRING HARNESS IS LOCATED. THIS WIRING HARNESS DOES NOT LOOK TO BE PROTECTED FROM WATER AND IT IS A MATER OF TIME BEFORE THE INSULATION ON THIS WIRE BREAKS DOWN AND SHORTS OUT TO THE FRAME. *TR
NHTSA ODI #10466950
102,000 miles · Jun 13, 2012
Electrical SystemEnginePower Train
WARNING LIGHT SAID ELECTRONIC THROTTLE CONTROL, THIS IS THE THIRD TIME I HAVE ALMOST HAD A MAJOR ACCIDENT AND FORD TELLS ME TO CALL THEM WHEN I HAVE AN ACCIDENT OR THE CODE SHOWS BACK UP. THEY ADMIT THAT THEY ARE AWARE OF THIS ISSUE BUT IT MUST FAIL COMPLETELY BEFORE IT CAN BE REPLACED UNDER WARRANTY OR RECALL. ALSO THE TRUCK C…
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WARNING LIGHT SAID ELECTRONIC THROTTLE CONTROL, THIS IS THE THIRD TIME I HAVE ALMOST HAD A MAJOR ACCIDENT AND FORD TELLS ME TO CALL THEM WHEN I HAVE AN ACCIDENT OR THE CODE SHOWS BACK UP. THEY ADMIT THAT THEY ARE AWARE OF THIS ISSUE BUT IT MUST FAIL COMPLETELY BEFORE IT CAN BE REPLACED UNDER WARRANTY OR RECALL. ALSO THE TRUCK CUTS OUT AT 60MPH AND JERKS UNTIL YOU SPEED UP. THEY ADVISED THEY ARE ALSO AWARE OF THIS PROBLEM AND COME BACK WHEN IT BREAKS DOWN. *TR
NHTSA ODI #10461641
120,000 miles · May 3, 2012
Electrical System
TL* THE CONTACT OWNS A 2005 FORD EXPEDITION. WHILE DRIVING APPROXIMATELY 30 MPH, THE VEHICLE SUDDENLY STALLED. THE ENGINE WARNING LIGHT ILLUMINATED ON THE INSTRUMENT PANEL AND A WARNING NOTIFICATION APPEARED, INDICATING THERE WAS A CHARGING SYSTEM FAILURE. THE VEHICLE WAS TOWED TO THE DEALER FOR DIAGNOSTIC TESTING AND THE TECHN…
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TL* THE CONTACT OWNS A 2005 FORD EXPEDITION. WHILE DRIVING APPROXIMATELY 30 MPH, THE VEHICLE SUDDENLY STALLED. THE ENGINE WARNING LIGHT ILLUMINATED ON THE INSTRUMENT PANEL AND A WARNING NOTIFICATION APPEARED, INDICATING THERE WAS A CHARGING SYSTEM FAILURE. THE VEHICLE WAS TOWED TO THE DEALER FOR DIAGNOSTIC TESTING AND THE TECHNICIAN STATED THE COMPUTER HAD TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE APPROXIMATE FAILURE MILEAGE WAS 120,000.
NHTSA ODI #10457376
88,000 miles · Mar 13, 2012
Electrical SystemFire
I WAS DRIVING ON FOUR LANE HIGHWAY IN RIGHT LANE AT 40MPH. I NOTICED THE CAR STARTING TO SLOW DOWN AND WHEN I PRESSED THE GAS PEDAL IT DID NOT REACT AND THE CAR CONTINUED TO SLOW DOWN. I LOOKED AT MY GAUGES ON THE DASH AND THERE WERE NO WARNING LIGHTS AND ALL GAUGES READ NORMALLY. I THOUGHT I COULD SMELL SMOKE, AND THE CAR CO…
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I WAS DRIVING ON FOUR LANE HIGHWAY IN RIGHT LANE AT 40MPH. I NOTICED THE CAR STARTING TO SLOW DOWN AND WHEN I PRESSED THE GAS PEDAL IT DID NOT REACT AND THE CAR CONTINUED TO SLOW DOWN. I LOOKED AT MY GAUGES ON THE DASH AND THERE WERE NO WARNING LIGHTS AND ALL GAUGES READ NORMALLY. I THOUGHT I COULD SMELL SMOKE, AND THE CAR CONTINUED TO SLOW DOWN, AND I KNEW I NEEDED TO GET OFF THE ROAD AS TRAFFIC WAS HEAVY. AS I PULLED OFF THE ROAD INTO THE PARKING LOT FOR THE STRIP MALL, THE CAR STALLED, LIGHTS CAME ON THE DASH TO INDICATE THE CAR STALLED AND I WAS ABLE TO STOP THE CAR, PUT IT IN PARK AND TURN THE CAR OFF. I COULD SMELL SMOKE AND I COULD SEE SMOKE GOING OUT THE CAR WINDOWS FROM INSIDE THE CAR AS I HAD THE WINDOWS OPEN A COUPLE OF INCHES. THERE WAS NO SMOKE COMING FROM UNDER THE HOOD. I DEBATED WHETHER TO CALL AAA OR 911. AS THE SMOKE INCREASED I CALLED 911. I THEN WENT TO THE CAR TO GET MY PURSE. WHEN I OPENED THE PASSENGER FRONT DOOR THE CAR WAS FILLED WITH SMOKE AND I THOUGHT I COULD SEE FIRE IN THE MIDDLE ROW OF SEAT ON THE FLOOR. I OPENED THE BACK DOOR ON THE PASSENGER SIDE AND SAW FLAMES SHOOTING UP FROM THE FLOOR 6 INCHES HIGH IN THE CENTER OF THE FLOOR. I TRIED TO PUT OUT THE FIRE WITH A SNOW SCRAPER WITH THE BRUSH END, BUT I WAS NOT SUCCESSFUL. I ASKED THE DRY CLEANING LADY IF SHE HAD A FIRE EXTINGUISHER. IT TOOK 30 SECONDS TO GET THE EXTINGUISHER AND ON MY WAY BACK TO THE CAR, I COULD SEE FLAMES UNDER THE CAR AND WHEN I OPENED THE BACK PASSENGER DOOR THE FIRE HAD SPREAD TO THE BACK SEAT. I WAS FEARFUL FOR HOW FAST THE FIRE SPREAD AND THE SMOKE PREVENTED ME FROM REACHING THE FIRE WITH THE EXTINGUISHER. THE FIRE DEPARTMENT THEN ARRIVED AND IT TOOK THEM 15-20 MINUTES TO PUT OUT THE FIRE AS THE FLAMES WERE SHOOTING AT LEAST 20 FEET INTO THE AIR. THE CAR WAS COMPLETELY ENGULFED IN FLAMES. I HAVE PICTURES I TOOK WITH MY PHONE. *TR
NHTSA ODI #10451540
77,850 miles · Feb 6, 2012
Electrical SystemVehicle Speed Control
I WAS DRIVING THE VEHICLE AND IT IMMEDIATELY LOST ACCELERATION. AN ALARM ON DASH IDENTIFIED THE PROBLEMS AS ELECTRONIC THROTTLE CONTROL FAILURE. THIS WAS VERY DANGEROUS AND I WAS LUCKY NO ONE WAS FOLLOWING ME CLOSE. MY WIFE IS NOW SCARED TO DRIVE THE VEHICLE AND I DON'T KNOW WHAT TO DO. THERE ARE MANY COMPLAINTS ON THE WEB ABOUT…
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I WAS DRIVING THE VEHICLE AND IT IMMEDIATELY LOST ACCELERATION. AN ALARM ON DASH IDENTIFIED THE PROBLEMS AS ELECTRONIC THROTTLE CONTROL FAILURE. THIS WAS VERY DANGEROUS AND I WAS LUCKY NO ONE WAS FOLLOWING ME CLOSE. MY WIFE IS NOW SCARED TO DRIVE THE VEHICLE AND I DON'T KNOW WHAT TO DO. THERE ARE MANY COMPLAINTS ON THE WEB ABOUT THIS ISSUE WHICH I WOULD HAVE THOUGHT A RECALL WOULD BE INITIATED BY FORD. I SEARCHED AND FOUND OUT THAT THERE WAS NO RECALL ON THIS ISSUE. I CALLED FORD MOTOR COMPANY AND THEY INFORMED ME THAT I WAS THE FIRST ONE TO COMPLAIN ABOUT THIS ISSUE. I FIND THAT VERY HARD TO BELIEVE WITH EVERYTHING I HAVE READ ON THE WEBSITE. ANYONE ONE WHO READS THIS THAT HAS HAD THE PROBLEM SHOULD CALL FORD MOTOR COMPANY AND COMPLAIN. JUST GO TO FORD.COM AND CLICK ON SUPPORT TO GET THE PHONE NUMBER. *TR
NHTSA ODI #10446871
67,000 miles · Feb 2, 2012
Electrical SystemFuel System, Gasoline
VEHICLE HAS BEEN STALLING FOR ALMOST A YEAR. VEHICLE SHUT OFF ON BUSY HIGHWAY AND TOWED TO NEARBY REPAIR SHOP. MECHANIC FOUND FUEL PUMP CONTROL MODULE COMPLETELY CORRODED FROM BEHIND AND CIRCUIT BOARD EXPOSED TO MOISTURE. THE FPCM FRIED AND SHORTED OUT ONE LEG OF THE FUEL PUMP. BOTH PIECES HAD TO BE REPLACED. NEW FPCM INSTALLE…
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VEHICLE HAS BEEN STALLING FOR ALMOST A YEAR. VEHICLE SHUT OFF ON BUSY HIGHWAY AND TOWED TO NEARBY REPAIR SHOP. MECHANIC FOUND FUEL PUMP CONTROL MODULE COMPLETELY CORRODED FROM BEHIND AND CIRCUIT BOARD EXPOSED TO MOISTURE. THE FPCM FRIED AND SHORTED OUT ONE LEG OF THE FUEL PUMP. BOTH PIECES HAD TO BE REPLACED. NEW FPCM INSTALLED WAS OBVIOUSLY REDESIGNED SO MODULE WOULD NOT SUFFER THIS FLAW AGAIN. I AM FINDING AN ALARMING AMOUNT OF COMPLAINTS ON THE INTERNET OF FORD EXPEDITION OWNER EXPERIENCING THE EXACT SAME PROBLEMS UNDER MORE DANGEROUS CONDITIONS. *KB
NHTSA ODI #10446313
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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