NHTSA owner reports · September 18, 2026 snapshot.
Engine complaints
57 reportsClear category filterMileage unknown · Mar 17, 2014
Electrical SystemEngineSteering
VEHICLE DIED UNEXPECTEDLY WHILE TRAVELING DOWN HIGHWAY AT A HIGH RATE OF SPEED. THERE ARE HUNDREDS OF COMPLAINTS JUST LIKE THIS ON HERE. IF A RECALL ISN'T IN ORDER PEOPLE WILL DIE AND THE LAWSUITS WILL BEGIN. IT'S OBVIOUSLY A MAJOR MECHANICAL PROBLEM. FORD AND THE NHTSA SHOULD BE LIABLE. THIS IS SERIOUS AND READING THROUGH A…
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VEHICLE DIED UNEXPECTEDLY WHILE TRAVELING DOWN HIGHWAY AT A HIGH RATE OF SPEED. THERE ARE HUNDREDS OF COMPLAINTS JUST LIKE THIS ON HERE. IF A RECALL ISN'T IN ORDER PEOPLE WILL DIE AND THE LAWSUITS WILL BEGIN. IT'S OBVIOUSLY A MAJOR MECHANICAL PROBLEM. FORD AND THE NHTSA SHOULD BE LIABLE. THIS IS SERIOUS AND READING THROUGH ALL OF THESE COMPLAINTS IT DOESN'T SEEM LIKE THE NHTSA IS DOING THEIR JOB. *TR
NHTSA ODI #10572716
117,000 miles · Feb 27, 2014
Engine
TL* THE CONTACT OWNS A 2005 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING 65 MPH, THE VEHICLE STALLED WITHOUT WARNING. THE WRENCH ICON ILLUMINATED AFTER THE FAILURE OCCURRED. THE CONTACT COASTED ONTO THE SHOULDER AND WAS ABLE TO RESTART THE ENGINE. THE VEHICLE WAS LATER TAKEN TO THE DEALER, WHO PERFORMED A DIAGNOSTIC…
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TL* THE CONTACT OWNS A 2005 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING 65 MPH, THE VEHICLE STALLED WITHOUT WARNING. THE WRENCH ICON ILLUMINATED AFTER THE FAILURE OCCURRED. THE CONTACT COASTED ONTO THE SHOULDER AND WAS ABLE TO RESTART THE ENGINE. THE VEHICLE WAS LATER TAKEN TO THE DEALER, WHO PERFORMED A DIAGNOSTIC AND LOCATED THE FAILURE AT THE THROTTLE. THE THROTTLE WAS REPLACED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE AND CURRENT MILEAGE WAS 117,000.
NHTSA ODI #10566261
78,000 miles · Dec 31, 2013
Electrical SystemEngineVehicle Speed Control
WHILE DRIVING 55MPH ON INTERSTATE 95 IN PHILADELPHIA, PA WITH MY WIFE AND 2 CHILDREN THE VEHICLE STOPPED RUNNING AND I WAS DANGEROUSLY STALLED IN THE MIDDLE OF INTERSTATE 95. THE CHECK ENGINE LIGHT CAME ON AND CHECK ELECTRONIC THROTTLE MESSAGE CAME ON. THIS IS A FAMILY VEHICLE AND MY WIFE AND I REFUSE TO DRIVE IT NOW IN FEAR O…
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WHILE DRIVING 55MPH ON INTERSTATE 95 IN PHILADELPHIA, PA WITH MY WIFE AND 2 CHILDREN THE VEHICLE STOPPED RUNNING AND I WAS DANGEROUSLY STALLED IN THE MIDDLE OF INTERSTATE 95. THE CHECK ENGINE LIGHT CAME ON AND CHECK ELECTRONIC THROTTLE MESSAGE CAME ON. THIS IS A FAMILY VEHICLE AND MY WIFE AND I REFUSE TO DRIVE IT NOW IN FEAR OF THIS INCIDENT OCCURRING AGAIN RESULTING IN DEATH OR SERIOUS INJURY. BASED UPON MY RESEARCH, IT APPEARS TO BE A WELL KNOWN PROBLEM THAT OCCURRED TO THOUSANDS OF FORD EXPEDITION OWNERS. I WOULD APPRECIATE THE PROBLEM BEING ADDRESSED EXPEDITIOUSLY BEFORE PEOPLE ARE KILLED AND/OR INJURED. *TR
NHTSA ODI #10557981
170,000 miles · Dec 17, 2013
EngineVehicle Speed Control
I HAVE SIX KIDS AND WHEN YOUR DRIVING AND YOUR CAR SHUTS OFF GOING 50-60 MILES AN HOURS AND GIVES YOU A MESSAGE FAIL SAFE MESSAGE, THAT'S PRETTY SCARY. I FIXED THE THROTTLE BODY SENSOR ONCE AND NOW HAVE ISSUES WITH THE SAME ISSUE. I HAVE LOOKED INTO THIS AND SURPRISED THAT THERE ARE NOT RECALLS. THIS IS ONE EXPENSIVE FIX. *TR
NHTSA ODI #10556436
144,500 miles · Dec 16, 2013
Engine
MY MOTHER HAD MY CAR WHEN THIS OCCURRED AND THE INCIDENT AND SUBSEQUENT RESEARCH SHOWING A DANGEROUS PATTERN AND NO RECALL OF THIS ISSUE HAS ME VERY CONCERNED. WHILE AT A RED LIGHT, THE ENGINE FAILSAFE MESSAGE FLASHED ACROSS THE DASH WITH THE ENGINE LIGHT ON WHILE MAKING LOUD ALERT BEEPS. THE ENGINE WAS STILL RUNNING BUT THE C…
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MY MOTHER HAD MY CAR WHEN THIS OCCURRED AND THE INCIDENT AND SUBSEQUENT RESEARCH SHOWING A DANGEROUS PATTERN AND NO RECALL OF THIS ISSUE HAS ME VERY CONCERNED. WHILE AT A RED LIGHT, THE ENGINE FAILSAFE MESSAGE FLASHED ACROSS THE DASH WITH THE ENGINE LIGHT ON WHILE MAKING LOUD ALERT BEEPS. THE ENGINE WAS STILL RUNNING BUT THE CAR WOULD NOT GO. MY MOTHER PUT IT IN PARK AND SHUT THE ENGINE OFF. SHE WAS ABLE TO RESTART THE CAR AND DRIVE WITH NO ISSUES. MY CONCERN DOING RESEARCH ON THIS ISSUE IS THAT THIS CAN OCCUR WHILE IN MOTION. IF THIS HAD HAPPENED A MINUTE EARLIER OR LATER, IT COULD HAVE RESULTED IN VERY SERIOUS ACCIDENTS DURING HIGH SPEEDS OR LEFT TURNS. I AM NOW ALMOST FEARFUL FOR MYSELF AND OTHERS TO DRIVE THIS CAR. *TR
NHTSA ODI #10556184
152,000 miles · Dec 9, 2013
Electrical SystemEngineService Brakes
I WAS DRIVING WITH 4 KIDS IN THE CAR, WHEN ALL THE SUDDEN MY CAR TURNED OFF, ALL THE LIGHTS CAME ON THE DASH. LUCKILY I WAS ABLE TO MOVE OVER TO A PARKING LOT. I TURNED THE CAR OFF, TURNED BACK ON, NOTHING. TRIED AGAIN AND IT WORKED. I WAS ABLE TO DRIVE 50 MILES HOME AND AS I WAS TURNING IN MY DRIVEWAY IT HAPPENED AGAIN. *TR
NHTSA ODI #10555394
85,000 miles · Jul 28, 2013
Engine
VEHICLE STOPPED RUNNING WHILE MAKING LEFT TURN AT INTERSECTION, VEHICLE STOPPED RUNNING WHILE AT STOP LIGHT, VEHICLE STOPPED RUNNING WHILE ON INTERSTATE HWY AT HIGHWAY SPEEDS. ALL THIS HAS HAPPENED MORE THAN 20 TIMES. *TR
NHTSA ODI #10532178
98,300 miles · Jul 15, 2013
EngineFire
TL* THE CONTACT OWNS A 2005 FORD EXPEDITION. THE CONTACT STATED THAT THE VEHICLE CAUGHT ON FIRE. THE FIRE STARTED FROM UNDER THE REAR SEAT OF THE VEHICLE. THE VEHICLE WAS DESTROYED IN THE FIRE. A POLICE REPORT WAS FILED. THE CONTACT STATED THAT HIS MECHANIC BELIEVED THAT A FAILED CATALYTIC CONVERTER COULD HAVE POTENTIALLY CAUSED…
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TL* THE CONTACT OWNS A 2005 FORD EXPEDITION. THE CONTACT STATED THAT THE VEHICLE CAUGHT ON FIRE. THE FIRE STARTED FROM UNDER THE REAR SEAT OF THE VEHICLE. THE VEHICLE WAS DESTROYED IN THE FIRE. A POLICE REPORT WAS FILED. THE CONTACT STATED THAT HIS MECHANIC BELIEVED THAT A FAILED CATALYTIC CONVERTER COULD HAVE POTENTIALLY CAUSED THE FIRE. THE FAILURE AND THE CURRENT MILEAGE WAS 98,300. *TR
NHTSA ODI #10524959
152,873 miles · Jul 1, 2013
Engine
I WAS DRIVING ON THE FREEWAY AT 60MPH AND THE ENGINE SHUT DOWN AND SHOWED "CHECK ELECTRIC THROTTLE CONTROL". I WAS NOT ABLE TO PULL TO THE SIDE. THE TRUCK WORKED FINE AFTER I RESTARTED IT. THIS HAS HAPPENED 5 TIMES. WE WERE LUCKY THAT NOBODY HIT US ON THE FREEWAY. THROTTLE BODY NEEDS TO BE REPLACED. 3 DIFFERENT MECHANICS AND 1 …
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I WAS DRIVING ON THE FREEWAY AT 60MPH AND THE ENGINE SHUT DOWN AND SHOWED "CHECK ELECTRIC THROTTLE CONTROL". I WAS NOT ABLE TO PULL TO THE SIDE. THE TRUCK WORKED FINE AFTER I RESTARTED IT. THIS HAS HAPPENED 5 TIMES. WE WERE LUCKY THAT NOBODY HIT US ON THE FREEWAY. THROTTLE BODY NEEDS TO BE REPLACED. 3 DIFFERENT MECHANICS AND 1 ELECTRICIAN SAID THIS A DEFECT AND THEY SEE IT ALL THE TIME WITH THIS ENGINE. *TR
NHTSA ODI #10522535
120,000 miles · Jun 4, 2013
Engine
I WAS DRIVING DOWN THE HIGHWAY GOING 65 & MY TRUCK COMPLETELY SHUT DOWN WAS ALMOST HIT BY A SEMI. A WRENCH SIGN CAME ON, I PUT IT IN PARK & SHUT IT OFF & STARTED IT BACK UP. THIS HAPPENS ALL THE TIME. I BELIEVE SOMETHING SHOULD BE DONE BEFORE SOMEONE GETS KILLED,FROM WHAT IM READING ITS HAPPENS TO ALOT OF OWNERS. SO PLEASE FOR O…
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I WAS DRIVING DOWN THE HIGHWAY GOING 65 & MY TRUCK COMPLETELY SHUT DOWN WAS ALMOST HIT BY A SEMI. A WRENCH SIGN CAME ON, I PUT IT IN PARK & SHUT IT OFF & STARTED IT BACK UP. THIS HAPPENS ALL THE TIME. I BELIEVE SOMETHING SHOULD BE DONE BEFORE SOMEONE GETS KILLED,FROM WHAT IM READING ITS HAPPENS TO ALOT OF OWNERS. SO PLEASE FOR OUR SAFETY DO SOMETHING DON'T WAIT TILL ITS TO LATE. *TR
NHTSA ODI #10515106
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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