NHTSA owner reports · September 18, 2026 snapshot.
Engine complaints
57 reportsClear category filter120,000 miles · Jun 25, 2016
EngineVehicle Speed Control
MY 2005 EXPEDITION IS MAINTAINED NORMALLY AND SPARK PLUGS CHANGED AND THE ENGINE WILL EITHER CUT OFF OR SLOW DOWN TO ABOUT 30 MILES AN HOUR WHILE I AM ON THE HIGHWAY WITH A ERROR MESSAGE FAIL SAVE MODE. MOST TIMES WHEN I SHUT OFF THE ENGINE AND RESTART IT TURNS OVER BUT DOESN'T STAY ON. TOTALLY UNSAFE FOR ME AND MY FAMILY. PLEAS…
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MY 2005 EXPEDITION IS MAINTAINED NORMALLY AND SPARK PLUGS CHANGED AND THE ENGINE WILL EITHER CUT OFF OR SLOW DOWN TO ABOUT 30 MILES AN HOUR WHILE I AM ON THE HIGHWAY WITH A ERROR MESSAGE FAIL SAVE MODE. MOST TIMES WHEN I SHUT OFF THE ENGINE AND RESTART IT TURNS OVER BUT DOESN'T STAY ON. TOTALLY UNSAFE FOR ME AND MY FAMILY. PLEASE RESEARCH AND RECALL WHAT THE ISSUE IS! THIS ISSUE HAS STARTED ABOUT 4 YEARS AFTER WE PURCHASED THE VEHICLE AND HAS BEEN HAPPENING MAYBE ONE TO TWO TIMES A MONTH SINCE.
NHTSA ODI #10876578
Mileage unknown · Jun 13, 2016
EngineFuel/propulsion System
FOR MANY TIME THAT MY EXPEDITION HAS STALLED BECAUSE OF THE THROTTLE BODY FAILING. THE ENGINE GOES INTO SAFE MODE AND STALLS AND STOPS, THI IS VERY DANGER SITUATION
NHTSA ODI #10873914
20 miles · Mar 28, 2016
Electrical SystemElectronic Stability Control (esc)Engine
I HAVE A 2005 FORD EXPEDITION AND HAVE MAINTAINED MY VEHICLE MAINTENANCE AND ONLY HAVE 124,000 MILES ON THIS VEHICLE. IT CONTINUES TO SHUT OFF THE ENGINE AND CODE FAIL SAFE MODE ON CODE APPEAR AND WHEN I'M DRIVING ON THE HIGHWAY IT IS DANGEROUS. AFTER READING SO MANY COMPLAINTS THIS IS UNSAFE. ALSO, THE COMPUTER ISSUES WITH …
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I HAVE A 2005 FORD EXPEDITION AND HAVE MAINTAINED MY VEHICLE MAINTENANCE AND ONLY HAVE 124,000 MILES ON THIS VEHICLE. IT CONTINUES TO SHUT OFF THE ENGINE AND CODE FAIL SAFE MODE ON CODE APPEAR AND WHEN I'M DRIVING ON THE HIGHWAY IT IS DANGEROUS. AFTER READING SO MANY COMPLAINTS THIS IS UNSAFE. ALSO, THE COMPUTER ISSUES WITH LOCKING DOORS, FAILURE OF THE TRANSMISSION (WHICH I HAD TO REPLACE) SUCH A DISAPPOINTMENT OF A VEHICLE. FORD SHOULD RECALL ENGINE AND COMPUTER ISSUES. I PURCHASED THIS VEHICLE BRAND NEW $50,000 + AND HAVE NOT BE ABLE TO DEPEND ON THE STABILITY SINCE I'VE HAD IT.
NHTSA ODI #10852059
65,000 miles · Aug 16, 2015
Engine
MY FORD EXPEDITION, WHILE DRIVING AT 40 MILES AN HOUR LOST POWER. THIS IS THE 3RD TIME IN 2 YEARS IT HAS HAPPENED. ON THE INFO CENTER IT STATED ENGINE FAIL SAFE MODE. THE THREE TIMES IT HAS HAPPENED HAS BEEN ON BACK ROADS.I CONSIDER THIS A VERY UNSAFE CONDITION . MY DEALER LOOKED AT IT THE FIRST TWO TIMES AND SAID THERE WERE NO …
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MY FORD EXPEDITION, WHILE DRIVING AT 40 MILES AN HOUR LOST POWER. THIS IS THE 3RD TIME IN 2 YEARS IT HAS HAPPENED. ON THE INFO CENTER IT STATED ENGINE FAIL SAFE MODE. THE THREE TIMES IT HAS HAPPENED HAS BEEN ON BACK ROADS.I CONSIDER THIS A VERY UNSAFE CONDITION . MY DEALER LOOKED AT IT THE FIRST TWO TIMES AND SAID THERE WERE NO CODES, THAT I WOULD NEED TO BRING IT IN SOONER. BUT THERE ARE NO LASTING RESULTS, AND IT STARTS RIGHT BACK UP.
NHTSA ODI #10748973
147,024 miles · Aug 14, 2015
Electrical SystemEnginePower Train
MY 15 YEAR OLD SON AND MY LIFE WERE PLACED IN SERIOUS DANGER, BY THE GROSS NEGLIGENCE AND DECEPTIVE BUSINESS PRACTICES PROMOTED BY THE FORD MOTOR COMPANY, REGARDING SCAN CODE P2106. SINCE AS EARLY AS FEBRUARY 26, 2013 FORD MOTOR COMPANY WAS MADE AWARE OF A DANGEROUS DEFECT CONCERNING THE MECHANICAL AND ELECTRICAL COMPONENTS OF …
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MY 15 YEAR OLD SON AND MY LIFE WERE PLACED IN SERIOUS DANGER, BY THE GROSS NEGLIGENCE AND DECEPTIVE BUSINESS PRACTICES PROMOTED BY THE FORD MOTOR COMPANY, REGARDING SCAN CODE P2106. SINCE AS EARLY AS FEBRUARY 26, 2013 FORD MOTOR COMPANY WAS MADE AWARE OF A DANGEROUS DEFECT CONCERNING THE MECHANICAL AND ELECTRICAL COMPONENTS OF THEIR MANUFACTURED PRODUCT RELEASED TO THE CONSUMER PUBLIC FOR PROFIT. THE VEHICLES ARE FORD TRUCKS, MANUFACTURED FROM 2003 - 2008, WITH THE V8 5.4 L ENGINE. PUBLIC RECORD REVEALS CASE NO. 12-7222, JASON SCHMIDT, (PLAINTIFF) VS. FORD MOTOR COMPANY, (DEFENDANT) FILED IN THE UNITED STATES DISTRICT COURT FOR THE EASTERN DISTRICT OF PENNSYLVANIA, THAT FORD MOTOR COMPANY IS WELL AWARE OF THIS ISSUE. I BELIEVE THAT FORD MOTOR COMPANY HAS MADE NO ATTEMPTS TO INFORM FORD DEALERSHIP OWNERS, THE FORD DEALERSHIP MANAGERS OR FORD SERVICE REPAIR SHOP MANAGERS AT THE FORD DEALERSHIPS AND CONSUMERS WHO HAD ALREADY PURCHASED THEIR MANUFACTURED PRODUCT OF THE ISSUE. THIS ISSUE IS VERY DANGEROUS, I WAS TRAVELING 70 MPH, WITH MY SON IN THE TRUCK. FORD MOTOR COMPANY HAS GONE ON RECORD, VIA TELEPHONE CONVERSATION, EXPLAINING TO ME THAT; "FORD MOTOR COMPANY HAS NO CONTROL OVER HOW INDIVIDUAL DEALERSHIPS FUNCTION OR OPERATE THEIR ESTABLISHMENT PLACES OF BUSINESS, SORRY. BUT I CAN TAKE A COMPLAINT AND BE SURE THAT THE DEALERSHIP RECEIVES IT AND PROVIDE YOU WITH A COMPLAINT NUMBER". FLAMMER FORD, SPRING HILL, FL REPLACED A PART AND NEGLECTED TO TEST DRIVE THE TRUCK, RELEASED THE VEHICLE TO ME AND THE PART REPLACED WAS NOT WHAT WAS WRONG WITH THE TRUCK. I HAD MY TRUCK TOWED TO AUTONATION FORD IN BROOKSVILLE, FL FOR THE SAME ISSUE (P2106 CODE), THEY DID THE SAME THING, WITHOUT REPLACING A THING. ONLY THIS TIME, WHILE DRIVING ON A HIGHWAY, MY TRUCK AND THE LOST ALL POWER. MY TRUCK IS BACK AT AUTONATION FORD IN NEED OF A NEW TRANSMISSION.
NHTSA ODI #10748773
111,520 miles · Jun 25, 2015
Electrical SystemEngine
WHILE MOVING IN TRAFFIC THE VEHICLE ENGINE CUT-OFF ON ITS OWN. MESSAGE CAME UP ON DASH DISPLAY, SOMETHING ABOUT "ELECT THROTTLE CONTROL". WAS MOVING VERY SLOWLY ON AN INTERSTATE HIGHWAY BAD TRAFFIC, WITH HEATERS (FRONT AND BACK) AND THE RADIO ON. I WAS ABLE TO COAST OFF TO THE SIDE OF THE HIGHWAY. TURNED OFF RADIO, HEATERS, THEN…
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WHILE MOVING IN TRAFFIC THE VEHICLE ENGINE CUT-OFF ON ITS OWN. MESSAGE CAME UP ON DASH DISPLAY, SOMETHING ABOUT "ELECT THROTTLE CONTROL". WAS MOVING VERY SLOWLY ON AN INTERSTATE HIGHWAY BAD TRAFFIC, WITH HEATERS (FRONT AND BACK) AND THE RADIO ON. I WAS ABLE TO COAST OFF TO THE SIDE OF THE HIGHWAY. TURNED OFF RADIO, HEATERS, THEN WAS ABLE TO RESTART THE VEHICLE. BATTERY CONDITION WAS FINE (REPLACED 2 YEARS AGO), NO OTHER WARNING. VEHICLE IS WELL-MAINTAINED, NEVER DRIVEN HARD OR USED FOR TOWING. TODAY I AM TAKING IT TO A FORD DEALER FOR EVALUATION.....UPDATED 08/25/15 *BF
NHTSA ODI #10730287
121,800 miles · Mar 12, 2015
Engine
TL* THE CONTACT OWNS A 2005 FORD EXPEDITION. WHILE DRIVING AT VARIOUS SPEEDS, THE ENGINE STALLED. THE VEHICLE WAS TAKEN TO A DEALER, WHO DIAGNOSED THAT THE THROTTLE BODY SENSOR NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 121,800.
NHTSA ODI #10693800
150,000 miles · Mar 12, 2015
EnginePower Train
SINCE PURCHASING THE EXPEDITION IN DECEMBER 2014, I'VE HAD SEVERAL INCIDENTS OF "CHECK ENGINE THROTTLE" WARNINGS AND THE ENGINE SHUT DOWN, SUDDENLY. THIS SEEMS TO ALSO HAVE A SECONDARY ISSUE OF THE TRUCK HESITATING/SPUTTERING AROUND 40-50MPH. THE VEHICLE HAS SHUT DOWN ON ME IN CITY TRAFFIC QUITE A FEW TIMES AND ONCE ON AN EXIT R…
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SINCE PURCHASING THE EXPEDITION IN DECEMBER 2014, I'VE HAD SEVERAL INCIDENTS OF "CHECK ENGINE THROTTLE" WARNINGS AND THE ENGINE SHUT DOWN, SUDDENLY. THIS SEEMS TO ALSO HAVE A SECONDARY ISSUE OF THE TRUCK HESITATING/SPUTTERING AROUND 40-50MPH. THE VEHICLE HAS SHUT DOWN ON ME IN CITY TRAFFIC QUITE A FEW TIMES AND ONCE ON AN EXIT RAMP OF THE HIGHWAY. THIS IS A VERY DANGEROUS SITUATION TO EXPERIENCE. THE DEALER MENTIONED POSSIBLE SPARK PLUG ISSUES. WHEN THE "CHECK ENGINE" ICON FINALLY CAME ON, I HAD IT READ BY THE DEALER AND AN INDEPENDENT MECHANIC. THE CODE IS A P2104. THE DEALER NEVER GOT BACK TO ME ON A REMEDY FOR THIS. THE MECHANIC SAYS THE ELECTRONIC THROTTLE CONTROL MUST BE REPLACED AND COULD BE THE CAUSE OF BOTH ISSUES. BOTH HAVE BEEN REPORTED TO THE DEALER BEFORE THEIR WARRANTY EXPIRED. I'M FINDING THE REPAIR COULD COST ABOUT $700. AN ISSUE OF THE ENGINE SHUTTING OFF, REGARDLESS OF SPEED, WHILE DRIVING IS VERY DANGEROUS. THE TRUCK MUST BE PLACED IN PARK, TURNED OFF, THE RE-STARTED BEFORE CONTINUING MY DRIVE. THE SCARIEST WAS UPON AN EXIT RAMP OF THE HIGHWAY AT APPROXIMATELY 30MPH. *TR
NHTSA ODI #10693758
176,000 miles · Feb 27, 2015
Engine
THIS IS THE 4TH TIME IN 5 WEEKS THAT MY CAR HAS SHUT DOWN WHILE DRIVING AND IT SAYS "ENGINE FAIL SAFE MODE". IT HAS BEEN IN THE SHOP AFTER THE FIRST 3 INCIDENTS AND DIFFERENT THINGS HAVE BEEN DONE TO IT. I JUST GOT IT OUT OF THE SHOP AND IT HAPPENED THE 4TH TIME. SO IT'S GOING BACK TO SHOP. I HAVE BEEN FORTUNATE, AND HAVE NOT BE…
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THIS IS THE 4TH TIME IN 5 WEEKS THAT MY CAR HAS SHUT DOWN WHILE DRIVING AND IT SAYS "ENGINE FAIL SAFE MODE". IT HAS BEEN IN THE SHOP AFTER THE FIRST 3 INCIDENTS AND DIFFERENT THINGS HAVE BEEN DONE TO IT. I JUST GOT IT OUT OF THE SHOP AND IT HAPPENED THE 4TH TIME. SO IT'S GOING BACK TO SHOP. I HAVE BEEN FORTUNATE, AND HAVE NOT BEEN IN A ACCIDENT AS A RESULT OF IT SHUTTING DOWN. LOOKING ONLINE IT'S AMAZING HOW MANY PEOPLE HAVE EXPERIENCED THIS SAME ISSUE. WHY HAS FORD OR NHTSA NOT DONE SOMETHING ABOUT THIS? WILL IT TAKE SOMEONE GETTING KILLED BEFORE THEY TAKE ACTION? *TR
NHTSA ODI #10691203
129,000 miles · Feb 5, 2015
EngineFuel/propulsion System
WHILE DRIVING THE VEHICLE WENT INTO A HEAVY VIBRATION FROM THE MOTOR AND THE SMELL OF RAW FUEL WAS PRESENT. AFTER TURNING OFF THE VEHICLE IT WOULD NOT START. THE VEHICLE WAS TOWED TO THE FORD DEALER AND THE DEALER STATED THAT A FUEL INJECTOR BECAME STUCK OPEN. THE INJECTOR FILLED THE CYLINDER WITH FUEL AND CAUSED THE ENGINE T…
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WHILE DRIVING THE VEHICLE WENT INTO A HEAVY VIBRATION FROM THE MOTOR AND THE SMELL OF RAW FUEL WAS PRESENT. AFTER TURNING OFF THE VEHICLE IT WOULD NOT START. THE VEHICLE WAS TOWED TO THE FORD DEALER AND THE DEALER STATED THAT A FUEL INJECTOR BECAME STUCK OPEN. THE INJECTOR FILLED THE CYLINDER WITH FUEL AND CAUSED THE ENGINE TO BLOW UP (SEVERE DAMAGE). IT WAS FOUND THAT THIS OCCURRED ON FORD EXPEDITIONS NUMEROUS TIMES AND FORD EXTENDED THE WARRANTY TO 11 YEARS, 120,000 MILES AND MY SCARY EXPERIENCE OCCURRED AT 129,000. I PREVIOUSLY REPLACED THE MOTOR AT MY OWN EXPENSE 2 YEARS PRIOR AND FORD DID NOT REPLACE THE INJECTORS OR NOTIFY ME OF AN INJECTOR ISSUE. FORD IS STATING THAT THEY WILL NOT HONOR THE WARRANTY AND THE ENGINE DAMAGE WAS CAUSED BY THE INJECTOR THAT WAS NOT REPLACED. IT WAS FOUND THAT FORD WAS AWARE OF THE INJECTOR ISSUE SINCE 2007. I'M NOT SURE THESE ISSUE ARE GETTING REPORTED. *TR
NHTSA ODI #10681481
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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