NHTSA owner reports · September 18, 2026 snapshot.
Engine And Engine Cooling complaints
47 reportsClear category filter72,000 miles · Sep 10, 2014
Engine And Engine CoolingCrash
TL* THE CONTACT OWNS A 2005 FORD EXPEDITION. THE CONTACT STATED THAT THE DRIVER CRASHED INTO ANOTHER VEHICLE THAT WAS PARKED. A POLICE REPORT WAS NOT FILED AND THERE WERE NO INJURIES REPORTED. THE VEHICLE WAS TAKEN TO A PRIVATE MECHANIC AND THE CONTACT WAS INFORMED THAT THE FRONT RADIATOR HAD BECOME ROTTEN. THE VEHICLE WAS NOT R…
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TL* THE CONTACT OWNS A 2005 FORD EXPEDITION. THE CONTACT STATED THAT THE DRIVER CRASHED INTO ANOTHER VEHICLE THAT WAS PARKED. A POLICE REPORT WAS NOT FILED AND THERE WERE NO INJURIES REPORTED. THE VEHICLE WAS TAKEN TO A PRIVATE MECHANIC AND THE CONTACT WAS INFORMED THAT THE FRONT RADIATOR HAD BECOME ROTTEN. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 72,000.
NHTSA ODI #10632264
112,550 miles · Jan 24, 2014
Engine And Engine CoolingFuel System, Gasoline
I WAS DRIVING MY 2005 FORD EXPEDITION EDDIE BAUER EDITION WHEN I STARTED TO MAKE A TURN. SUDDENLY THE VEHICLE STOPPED MOVING AND AN INDICATOR LIGHT STATING "ENGINE FAIL SAFE MODE" CAME ON. DURING THE TURN, A VEHICLE WAS COMING TOWARD ME AND I BARELY HAD ENOUGH TIME TO GET MY VEHICLE OUT OF THE LANE BEFORE I GOT HIT. I HAD TO STO…
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I WAS DRIVING MY 2005 FORD EXPEDITION EDDIE BAUER EDITION WHEN I STARTED TO MAKE A TURN. SUDDENLY THE VEHICLE STOPPED MOVING AND AN INDICATOR LIGHT STATING "ENGINE FAIL SAFE MODE" CAME ON. DURING THE TURN, A VEHICLE WAS COMING TOWARD ME AND I BARELY HAD ENOUGH TIME TO GET MY VEHICLE OUT OF THE LANE BEFORE I GOT HIT. I HAD TO STOP MY VEHICLE, PUT IT IN PARK (WHILE SITTING ON THE ROADWAY), SHUT IT OFF, AND RESTART IT BEFORE I COULD MOVE AGAIN. IT RAN FINE FOR A COUPLE OF DAYS AND THEN IT HAPPENED TO ME AGAIN WHILE DRIVING. THIS IS A VERY DANGEROUS SITUATION THAT SHOULD BE LOOKED INTO AND AFTER CHECKING THE INTERNET IT SEEMS THERE ARE LOTS OF PEOPLE WITH THE SAME EXPERIENCES. I TOOK MY VEHICLE TO THE SHOP AND THEY TOLD ME IT WAS THE THROTTLE BODY. AFTER SPENDING $409.00 (BECAUSE OF COURSE IT WAS NOT COVERED BY MY WARRANTY) TO REPAIR IT HOPEFULLY THE PROBLEM MAY BE FIXED. I FIGURED SPENDING THE MONEY WAS BETTER THAN THE OPTION OF POSSIBLY GETTING IN A SERIOUS ACCIDENT AND BEING KILLED IF THE PROBLEM WAS NOT FIXED. SOMEBODY NEEDS TO LOOK INTO THIS PROBLEM WITH THE VEHICLE AND MAKE FORD RESPONSIBLE FOR COSTS SINCE IT IS OBVIOUSLY A DEFECT IN THE VEHICLE. *TR
NHTSA ODI #10561395
122,000 miles · Jan 26, 2013
Engine And Engine CoolingPower Train
DRIVING IN CITY TRAFFIC, AT APPROXIMATELY 35 MPH. THE ELECTRONIC THROTTLE CONTROL LIGHT CAME ON AND ENGINE DIED. WE WERE ABLE TO COAST TO GAS STATION. THE VEHICLE STARTED RIGHT UP AND EVERYTHINGS WORKED FINE. THE NEXT DAY TOOK VEHICLE TO FORD DEALERSHIP. AFTER TROUBLESHOOTING, THEY WERE NOT REALLY SURE OF WHAT WAS THE PROBLE…
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DRIVING IN CITY TRAFFIC, AT APPROXIMATELY 35 MPH. THE ELECTRONIC THROTTLE CONTROL LIGHT CAME ON AND ENGINE DIED. WE WERE ABLE TO COAST TO GAS STATION. THE VEHICLE STARTED RIGHT UP AND EVERYTHINGS WORKED FINE. THE NEXT DAY TOOK VEHICLE TO FORD DEALERSHIP. AFTER TROUBLESHOOTING, THEY WERE NOT REALLY SURE OF WHAT WAS THE PROBLEM. BUT THEY SUGGESTED CHANGING THE THROTTLE BODY. WE DECIDED TO TAKE VEHICLE HOME. VEHICLE WORKED FINE UNTIL YESTERDAY, THE PROBLEM OCCURRED AGAIN. THIS IS AN UNSAFE CONDITION. THERE IS A LARGE ABOUT OF E-MAIL TRAFFIC ABOUT THIS SAME PROBLEM, AND FORD HAS NOT ISSUED A RECALL. *TR
NHTSA ODI #10494791
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
45,000 miles · Apr 29, 2012
Engine And Engine CoolingFuel System, Gasoline
ENGINE STOPS RUNNING AT DIFFERENT SPEEDS. SYSTEM DISPLAYS A CHECK ELECTRONIC THROTTLE CONTROL ERROR. THIS IS VERY DANGEROUS. *TR
NHTSA ODI #10456808
80,000 miles · Mar 15, 2012
Engine And Engine Cooling
TL* THE CONTACT OWNS A 2005 FORD EXPEDITION. WHILE DRIVING APPROXIMATELY 55 MPH, THE ENGINE STALLED WITH THE ILLUMINATION OF THE WARNING INDICATOR. THE ENGINE RESTARTED AFTER WAITING A FEW MOMENTS AND RESUMED AS NORMAL. THE FAILURE RECURRED THREE TIMES WHILE DRIVING AT VARIOUS SPEEDS. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECH…
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TL* THE CONTACT OWNS A 2005 FORD EXPEDITION. WHILE DRIVING APPROXIMATELY 55 MPH, THE ENGINE STALLED WITH THE ILLUMINATION OF THE WARNING INDICATOR. THE ENGINE RESTARTED AFTER WAITING A FEW MOMENTS AND RESUMED AS NORMAL. THE FAILURE RECURRED THREE TIMES WHILE DRIVING AT VARIOUS SPEEDS. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC FOR DIAGNOSIS BUT THEY WERE UNABLE TO DETECT A FAILURE CODE. THE MANUFACTURER WAS NOTIFIED OF THE PROBLEM. THE APPROXIMATE FAILURE MILEAGE WAS 80,000.
NHTSA ODI #10451784
101,000 miles · Feb 6, 2012
Engine And Engine Cooling
TL* THE CONTACT OWNS A 2005 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING 35 MPH, THE VEHICLE WOULD ENGAGE INTO SAFE MODE ERRONEOUSLY AND STALL. THE CONTACT HAD TO SHUT OFF AND RESTART THE VEHICLE IN ORDER TO HAVE THE VEHICLE FUNCTION PROPERLY. THE CONTACT DID NOT TAKE THE VEHICLE TO THE DEALER FOR A DIAGNOSTIC TEST …
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TL* THE CONTACT OWNS A 2005 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING 35 MPH, THE VEHICLE WOULD ENGAGE INTO SAFE MODE ERRONEOUSLY AND STALL. THE CONTACT HAD TO SHUT OFF AND RESTART THE VEHICLE IN ORDER TO HAVE THE VEHICLE FUNCTION PROPERLY. THE CONTACT DID NOT TAKE THE VEHICLE TO THE DEALER FOR A DIAGNOSTIC TEST OR REPAIRS. THE CONTACT CALLED THE MANUFACTURER AND FILED A COMPLAINT. THE FAILURE MILEAGE WAS 101,000.
NHTSA ODI #10446807
76,000 miles · Jan 22, 2012
Engine And Engine CoolingVehicle Speed Control
I WAS DRIVING MY CAR WHEN ALL OF A SUDDEN THE ACCELERATOR IS NOT RESPONDING AND SO I NEED TO COAST THE CAR TO THE CURVE. I CALLED THE DEALER AND SO MY CAR WAS STILL UNDER MY EXTENDED WARRANTY AND SO I TOOK THE CAR IN AND I WAS TOLD THAT THEY REPLACED THE PART THIS WAS IN MARCH 2009, IT IS NOW JANUARY 21, 2012 AND I HAD THE SAME…
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I WAS DRIVING MY CAR WHEN ALL OF A SUDDEN THE ACCELERATOR IS NOT RESPONDING AND SO I NEED TO COAST THE CAR TO THE CURVE. I CALLED THE DEALER AND SO MY CAR WAS STILL UNDER MY EXTENDED WARRANTY AND SO I TOOK THE CAR IN AND I WAS TOLD THAT THEY REPLACED THE PART THIS WAS IN MARCH 2009, IT IS NOW JANUARY 21, 2012 AND I HAD THE SAME PROBLEM. THE MESSAGE BOARD READS, CHECK ELECTRONIC THROTTLE SYSTEM. *TR
NHTSA ODI #10444763
Mileage unknown · Sep 19, 2011
Engine And Engine CoolingPower TrainVehicle Speed Control
WHILE DRIVING AT 60MPH ON US 85 N THE ENGINE LIGHT CAME ON WITH A MESSAGE "CHECK ELECTRONIC THROTTLE CONTROL" THE SPEED BEGAN TO DROP AND I COULD NOT ACCELERATE. I BEGAN TO MERGE TO THE RIGHT TO THE EMERGENCY LANE. I TURNED OFF THE ENGINE AND STARTED AGAIN. THEN I DROVE THE VEHICLE HOME. IT WAS A VERY SCARY EXPERIENCE I COU…
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WHILE DRIVING AT 60MPH ON US 85 N THE ENGINE LIGHT CAME ON WITH A MESSAGE "CHECK ELECTRONIC THROTTLE CONTROL" THE SPEED BEGAN TO DROP AND I COULD NOT ACCELERATE. I BEGAN TO MERGE TO THE RIGHT TO THE EMERGENCY LANE. I TURNED OFF THE ENGINE AND STARTED AGAIN. THEN I DROVE THE VEHICLE HOME. IT WAS A VERY SCARY EXPERIENCE I COULD HAVE BEEN IN AN ACCIDENT. IT WAS VERY DANGEROUS. THIS SHOULD BE A RECALL PROBLEM. *KB
NHTSA ODI #10426374
101,000 miles · Sep 18, 2011
Electrical SystemEngine And Engine Cooling
2005 EXPEDITION RANDOMLY STALLS AT VARIOUS SPEEDS USUALLY AROUND 45 - 50 MILES PER HOUR. YOU HAVE TO TRY TO GET TO THE SIDE OF THE ROAD, STOP AND GIVE THE CAR A COUPLE OF MINUTES AND CRANK IT AGAIN. I HAVE TAKEN TO FORD DEALERSHIP AND I NEED A THROTTLE POSITION SENSOR. IT WILL BE $700 TO FIX. THE PERSON THAT OWNED THE VEHICL…
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2005 EXPEDITION RANDOMLY STALLS AT VARIOUS SPEEDS USUALLY AROUND 45 - 50 MILES PER HOUR. YOU HAVE TO TRY TO GET TO THE SIDE OF THE ROAD, STOP AND GIVE THE CAR A COUPLE OF MINUTES AND CRANK IT AGAIN. I HAVE TAKEN TO FORD DEALERSHIP AND I NEED A THROTTLE POSITION SENSOR. IT WILL BE $700 TO FIX. THE PERSON THAT OWNED THE VEHICLE BEFORE ME HAD ALREADY REPLACED THIS SAME PART. MY CONCERN IS I SPEND THE $700 AND STILL HAVE THE SAME PROBLEM. THIS IS A SERIOUS SAFETY ISSUE, I STAY IN CONSTANT FEAR THAT IT IS GOING TO STALL AT ANY MINUTE. I CAN'T BELIEVE FORD HAS NOT RECALLED THIS. THIS IS MY SECOND FORD BUT WILL BE MY LAST. *TT
NHTSA ODI #10425983
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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