← New search

2005 Ford Expedition

Owner reports · Recalls · Investigations

More warning signs than most Expedition years

Owner complaints for the 2005 Ford Expedition are substantially higher than the model-year median of 155.

About this comparison →

When problems were reported

Mileage at the reported incident

289 reports with mileage · 26 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.

  • Electrical System. Review the 76 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Vehicle Speed Control. Review the 66 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Engine. Review the 57 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

20 crash reports6 fire reports10 injury reports

Engine And Engine Cooling complaints

47 reports
Clear category filter
31,500 miles · Jun 10, 2010
Engine And Engine Cooling

TL*THE CONTACT OWNS A 2005 FORD EXPEDITION. WHILE DRIVING 50-55 MPH THE VEHICLE STALLED IN THE MIDDLE OF THE ROAD AND THE CHECK ELECTRONIC THROTTLE WARNING LIGHT ILLUMINATED ON THE INSTRUMENT PANEL. SHE WAITED A FEW SECONDS AND TURNED THE VEHICLE BACK ON AND IT BEGAN TO FUNCTION NORMALLY. THE FAILURE OCCURRED TWICE. THE VEHICLE …

Read full complaint

TL*THE CONTACT OWNS A 2005 FORD EXPEDITION. WHILE DRIVING 50-55 MPH THE VEHICLE STALLED IN THE MIDDLE OF THE ROAD AND THE CHECK ELECTRONIC THROTTLE WARNING LIGHT ILLUMINATED ON THE INSTRUMENT PANEL. SHE WAITED A FEW SECONDS AND TURNED THE VEHICLE BACK ON AND IT BEGAN TO FUNCTION NORMALLY. THE FAILURE OCCURRED TWICE. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER WHO WAS UNABLE TO DIAGNOSE OR DUPLICATE THE FAILURE. THE FAILURE MILEAGE WAS 31,500 AND THE CURRENT MILEAGE WAS 31,750.

NHTSA ODI #10335630

96,000 miles · Apr 25, 2010
Engine And Engine Cooling

ORIGINAL FACTORY SPARK PLUG BACKED OUT FROM CYLINDER HEAD. CHECKED REMAINING 7 SPARK PLUGS. FOUR OF SEVEN LOOSE. MECHANIC RECOMMENDED USING HELI COIL KIT ON ALL SPARK PLUG THREADS. MECHANIC MENTIONED THAT THIS WAS A COMMON OCCURRENCE ON FORD 5.4 LITER ENGINES. IF THIS IS TRUE, IT APPEARS AS THOUGH A RECALL SHOULD BE REQUIRED FOR…

Read full complaint

ORIGINAL FACTORY SPARK PLUG BACKED OUT FROM CYLINDER HEAD. CHECKED REMAINING 7 SPARK PLUGS. FOUR OF SEVEN LOOSE. MECHANIC RECOMMENDED USING HELI COIL KIT ON ALL SPARK PLUG THREADS. MECHANIC MENTIONED THAT THIS WAS A COMMON OCCURRENCE ON FORD 5.4 LITER ENGINES. IF THIS IS TRUE, IT APPEARS AS THOUGH A RECALL SHOULD BE REQUIRED FOR REPAIR OF CYLINDER HEADS. *TR

NHTSA ODI #10327351

94,189 miles · Apr 22, 2010
Engine And Engine Cooling

MY 2005 FORD EXPEDITION WAS CUTTING OFF AND TICKING EVERYDAY, BUT NO LIGHTS WERE COMING ON TO TELL ME WHAT IT WAS, I TOOK MY VEHICLE TO PEP BOYS SHOP AND THEY DECLINE TO FIX IT DO TO SPARK PLUGS BREAKING IN THE ENGINE, SO I TOOK IT TO THE FORD DEALER WHERE I PURCHASED IT. IT TOOK THEM A WHOLE DAY TO FIGURE OUT WHAT WAS WRONG WIT…

Read full complaint

MY 2005 FORD EXPEDITION WAS CUTTING OFF AND TICKING EVERYDAY, BUT NO LIGHTS WERE COMING ON TO TELL ME WHAT IT WAS, I TOOK MY VEHICLE TO PEP BOYS SHOP AND THEY DECLINE TO FIX IT DO TO SPARK PLUGS BREAKING IN THE ENGINE, SO I TOOK IT TO THE FORD DEALER WHERE I PURCHASED IT. IT TOOK THEM A WHOLE DAY TO FIGURE OUT WHAT WAS WRONG WITH IT, THEY SAID I NEEDED A TUNE UP WHICH WAS $279, AND HE TOLD ME THAT ALL OF SPARK PLUGS NEEDED TO BE REPLACED AND THAT THEY SOMETIMES BREAK OFF IN THE ENGINE AND IF THAT WHERE TO HAPPEN IT WOULD BE A ADDITIONAL $90 PER PLUG, THE COIL NEEDED TO REPLACED $95, AND THE ON OF THE CYLINDER NEED TO BE REPLACED UNKNOWN AMOUNT/FORGOT, THEN THEY CALL ME BACK AND TOLD ME THAT ALL OF THE SPARK PLUGS HAD BROKE. THE FORD DEALERSHIP REPAIRED MY TRUCK CAUSE THERE WHERE OTHER PROBLEMS AS WELL SO TOTAL $1000 IN REPAIRS FOR A PROBLEM THAT I NEVER NEW THIS TRUCK WAS HAVING. *TR

NHTSA ODI #10327018

72,000 miles · Apr 6, 2010
Engine And Engine Cooling

MY 2005 FORD EXPEDITION SUDDENLY AND UNEXPECTEDLY SHUT OFF IN THE MIDDLE OF THE HIGHWAY. AN ERROR CODE OF "CHECK ELECTRONIC THROTTLE" DISPLAYS ON THE DASH AND A WARNING SIGNAL SOUNDS. ALL WHILE THE VEHICLE LOSES THE ABILITY TO ACCELERATE AND POWER STEERING. AFTER BRINGING THE VEHICLE TO A STOP, IT CRANKS RIGHT UP AS IF THERE WAS…

Read full complaint

MY 2005 FORD EXPEDITION SUDDENLY AND UNEXPECTEDLY SHUT OFF IN THE MIDDLE OF THE HIGHWAY. AN ERROR CODE OF "CHECK ELECTRONIC THROTTLE" DISPLAYS ON THE DASH AND A WARNING SIGNAL SOUNDS. ALL WHILE THE VEHICLE LOSES THE ABILITY TO ACCELERATE AND POWER STEERING. AFTER BRINGING THE VEHICLE TO A STOP, IT CRANKS RIGHT UP AS IF THERE WAS NEVER A PROBLEM. IT HAS NOW DONE THIS ABOUT 5 OR 6 TIMES. WE HAVE NEARLY BEEN HIT TWICE BY 18 WHEELERS AS A RESULT OF THIS. THIS IS AN EXTREMELY DANGEROUS PROBLEM. I HAVE RESEARCHED THE PROBLEM ONLINE IN HOPES OF FINDING OUT WHAT COULD BE CAUSING THE PROBLEM. TO MY HORROR, I FOUND HUNDREDS OF SIMILAR COMPLAINTS ALL LINKED TO THE 2005 FORD EXPEDITION ONLY. I HAVE NOT SEEN THIS TYPE OF COMPLAINT FOR ANY OTHER MODEL YEAR. I'M LEARY OF EVEN TAKING IT TO A DEALERSHIP FOR THE PROBLEM AT THIS POINT BECAUSE THE COMMENTS AROUND THE ISSUES HAVE BEEN THAT FORD HAS REPLACED THE "THROTTLE BODY" AND IN SOME CASES IT DIDN'T RESOLVE THE PROBLEM. TO ME IT SOUNDS LIKE A RECALL IS NEEDED TO ADDRESS THIS ISSUE. IT SHOULDN'T TAKE A SEVERE ACCIDENT OR DEATH TO REMEDY THIS SITUATION. IT SOUNDS LIKE FORD IS TRYING TO AVOID ISSUING A RECALL ON THIS FROM THE COMPLAINTS THAT I HAVE REVIEWED. IF THE 2005 FORD EXPEDITION IS THE ONLY MODEL YEAR AFFECTED, THEN THERE IS SOMETHING THAT WAS PROGRAMMED OR INSTALLED INCORRECTLY ON THE FORD EXPEDITIONS FROM THAT MODEL YEAR. AN INVESTIGATION NEEDS TO BE INITIATED BEFORE THE FATAL RESULTS THAT TOYOTA HAS HAD RECENTLY BECOME A PART OF FORDS FUTURE, AND ALL BECAUSE THEY WANT TO BE IN DENIAL OF A PROBLEM WHICH SHOULD INITIATE A RECALL TO FIX. *TR

NHTSA ODI #10324024

99,000 miles · Mar 10, 2010
Engine And Engine CoolingVehicle Speed Control

2005 FORD EXPEDITION WITH 90,000 MILES ON IT, DRIVEN IN NORMAL VEHICLE STALLS WHILE DRIVING UNDER NORMAL CONDITIONS, AND THE "CHECK ELECTRONIC THROTTLE CONTROL" MESSAGE COMES ON INFOR SCREEN, THEN ENGINE LIGHT COMES ON. ALMOST RAN INTO DITCH ALONG SIDE OF ROAD LAST TIME WHEN ENGINE STALLED, AS POWER STEERING AND BRAKES SHUT DO…

Read full complaint

2005 FORD EXPEDITION WITH 90,000 MILES ON IT, DRIVEN IN NORMAL VEHICLE STALLS WHILE DRIVING UNDER NORMAL CONDITIONS, AND THE "CHECK ELECTRONIC THROTTLE CONTROL" MESSAGE COMES ON INFOR SCREEN, THEN ENGINE LIGHT COMES ON. ALMOST RAN INTO DITCH ALONG SIDE OF ROAD LAST TIME WHEN ENGINE STALLED, AS POWER STEERING AND BRAKES SHUT DOWN AS WELL. *TR

NHTSA ODI #10318468

75,200 miles · Feb 8, 2010
Engine And Engine Cooling

UNTIL TODAY I HAVE BEEN A LOYAL FORD VEHICLE OWNER. MY WIFE WAS TAKING OUR THREE CHILDREN TO SCHOOL THIS MORNING AND AS SHE WAS MERGING ONTO THE HIGHWAY SHE WAS ALERTED TO AN UNFAMILIAR CODE AND ALARM IN THE VEHICLE. BEFORE SHE COULD LOOK AT THE DASHBOARD THE VEHICLE LOST ALL POWER AND WOULD NOT ACCELERATE IN THE ACCELERATION LA…

Read full complaint

UNTIL TODAY I HAVE BEEN A LOYAL FORD VEHICLE OWNER. MY WIFE WAS TAKING OUR THREE CHILDREN TO SCHOOL THIS MORNING AND AS SHE WAS MERGING ONTO THE HIGHWAY SHE WAS ALERTED TO AN UNFAMILIAR CODE AND ALARM IN THE VEHICLE. BEFORE SHE COULD LOOK AT THE DASHBOARD THE VEHICLE LOST ALL POWER AND WOULD NOT ACCELERATE IN THE ACCELERATION LANE, THE BRAKING AND STEERING BECAME MINIMAL AND SHE WAS LEFT WITH A LITTLE MORE THAN A DISABLED VEHICLE ON THE HIGHWAY. WITH HEAVY RUSH HOUR TRAFFIC RAPIDLY APPROACHING HER AND UNSURE WHETHER THEY COULD STOP SHE HAD TO FORCE THE VEHICLE TO THE EDGE OF THE GUARDRAIL. THE VEHICLE WHEN TURNED OFF AND RESTARTED APPEARED NORMAL. I THEN CHECKED PRIOR COMPLAINTS ON THIS WEB SITE AND OTHERS AND AM APPALLED OF THE LACK OF ACTION BY FORD MOTOR COMPANY AND OTHERS FOR NOT LOOKING INTO THIS ISSUE. THE LIVES OF THREE SMALL CHILDREN AND WHOEVER ELSE MAY HAVE BEEN INVOLVED IN THIS POTENTIAL COLLISION DESERVE TO HAVE FORD ACKNOWLEDGE THIS PROBLEM. I PURCHASED THE EXTENDED WARRANTY FROM FORD AND WHEN I TALKED ON THE PHONE WITH THEM THIS MORNING, THEY TOLD ME THAT THEY WOULD JUST "KEEP AN EYE ON IT". WHEN THEY LOOKED ON THE COMPUTER TO INFORM ME MY WARRANTY HAD EXPIRED 200 MILES AGO THEY CHANGED THEIR MIND AND TOLD ME TO BRING IT IN. PLEASE, PLEASE LOOK INTO THIS OBVIOUS DEFECT. I AM A POLICE OFFICER AND SEE TOO MANY FATALITIES DUE TO OTHER CONTRIBUTING FACTORS. I WOULD NOT WANT TO SEE ONE BECAUSE OF AN ORGANIZATION FAILING TO TAKE ACCOUNTABILITY.

NHTSA ODI #10307367

56,261 miles · Dec 30, 2009
Engine And Engine Cooling

1. THERE WERE NO EVENTS LEADING UP TO THE FAILURE. THERE IS NO WARNING THAT THIS IS GOING TO HAPPEN OR IS HAPPENING. UNDER NORMAL DRIVING CONDITIONS, MY 2005 FORD EXPEDITION SIMPLY LOST ALL POWER AND THE WORDS "ENGINE FAIL SAFE MODE" APPEARED. 2. THIS OCCURRED TWICE (OCT. 6, 2009 AND NOV. 16, 2009). I WAS ABLE TO PULL TO…

Read full complaint

1. THERE WERE NO EVENTS LEADING UP TO THE FAILURE. THERE IS NO WARNING THAT THIS IS GOING TO HAPPEN OR IS HAPPENING. UNDER NORMAL DRIVING CONDITIONS, MY 2005 FORD EXPEDITION SIMPLY LOST ALL POWER AND THE WORDS "ENGINE FAIL SAFE MODE" APPEARED. 2. THIS OCCURRED TWICE (OCT. 6, 2009 AND NOV. 16, 2009). I WAS ABLE TO PULL TO THE SIDE OF THE ROAD BOTH TIMES BUT DURING THE SECOND INCIDENT, I LOST THE POWER STEERING AS WELL AND STRUGGLED TO PULL OVER. THE CONSEQUENCES OF THIS "ENGINE FAIL SAFE MODE" IS THAT THE CAR STOPS WORKING. YOU BECOME A SITTING DUCK WHEREVER THE CAR HAS DECIDED TO GO INTO THIS MODE. YOU ARE UNABLE TO ACCELERATE -NOT FUN WHEN THIS HAPPENED ON THE FREEWAY THE FIRST TIME-AND IF YOU DO NOT LOSE YOUR POWER STEERING, YOU CAN PULL TO THE SIDE OF THE ROAD. 3. THE ELECTRONIC THROTTLE BODY WAS REPLACED FOR APPROXIMATELY $700. NOWHERE IN THE CAR MANUAL DOES IT LET YOU KNOW THAT THIS CODE COULD LEAD TO THIS REPAIR. I HAD A HARD TIME FIGURING OUT WHAT THE CODE MEANT USING THE OWNER MANUAL. THE MOST FRUSTRATING PART OF THIS FAILURE IS THAT IF THIS HAD OCCURRED WHEN I WAS TRAVELING AT 65 MPH ON THE FREEWAY, I PROBABLY WOULD NOT BE HERE TO ENTER THIS COMPLAINT. I WOULD LIKE TO PREVENT THIS FROM HAPPENING TO SOMEONE ELSE. *TR

NHTSA ODI #10297596

127,000 miles · Nov 6, 2009
Engine And Engine CoolingFuel System, Other

2005 FORD EXPEDITION 5.4 ENGINE, MISFIRING 3&5 CYLINDER. ROUGH IDLE. CAR HAS 127,000 MILES AND SINCE WE HAVE HAD IT I HAD ISSUES WITH IT IDLING IN PARK AND ALMOST AT TIMES WANTING TO STALL. ENGINE HAS ON MORE THAN 3 OCCASIONS WHILE DRIVING 60-70 MPH ON THE HIGHWAY BECOME UN RESPONSIVE WHILE DRIVING. ENGINE WOULD RUN BUT NO ACCEL…

Read full complaint

2005 FORD EXPEDITION 5.4 ENGINE, MISFIRING 3&5 CYLINDER. ROUGH IDLE. CAR HAS 127,000 MILES AND SINCE WE HAVE HAD IT I HAD ISSUES WITH IT IDLING IN PARK AND ALMOST AT TIMES WANTING TO STALL. ENGINE HAS ON MORE THAN 3 OCCASIONS WHILE DRIVING 60-70 MPH ON THE HIGHWAY BECOME UN RESPONSIVE WHILE DRIVING. ENGINE WOULD RUN BUT NO ACCELERATION WHEN THE GAS PEDAL WAS PUSHED; IT WAS LIKE THE CAR WAS RUNNING IN NEUTRAL. INDICATOR LIGHT CAME ON SHOWING "ENGINE FAILURE". PULLED OFF THE ROAD AND RESTARTED CAR AND THEN IT RAN FINE AGAIN. FORD SVC DEPT. COULD NOT REPLICATE THE SITUATION WHEN I TOOK IT TO THEM, SO IT WAS NEVER REPAIRED. (CLEARLY THERE IS A FAULTY PROBLEM) CURRENTLY CAR IS IN THE SHOP REPLACING ALL 8 SPARK PLUGS, COILS AND BOOTS. MECHANIC INDICATED A LOT OF CARBON BUILDUP IN THROTTLE BODY. (SEEMS TO ME POSSIBLY SOME OTHER FAULTY COMPONENT COULD BE WHY I'M HAVING TO SPEND $800 TO FULLY REPAIR MY CAR). *TR

NHTSA ODI #10291248

64,721 miles · Oct 30, 2009
Engine And Engine CoolingFuel System, Other

2005 FORD EXPEDITION DISPLAYED "ELECTRONIC THROTTLE CONTROL FAILURE" MESSAGE AND ENGINE ABRUPTLY QUIT AT HIGH SPEED IN TRAFFIC ON A CURVED ROAD RESULTING IN A SIMULTANEOUS LOSS OF POWER STEERING AND POWER BRAKES. THIS APPEAR TO BE A COMMON PROBLEM FOR WHICH THERE HAS BEEN NO SAFETY RECALL. A FAILURE LIKE THIS WITH NO MECHANICA…

Read full complaint

2005 FORD EXPEDITION DISPLAYED "ELECTRONIC THROTTLE CONTROL FAILURE" MESSAGE AND ENGINE ABRUPTLY QUIT AT HIGH SPEED IN TRAFFIC ON A CURVED ROAD RESULTING IN A SIMULTANEOUS LOSS OF POWER STEERING AND POWER BRAKES. THIS APPEAR TO BE A COMMON PROBLEM FOR WHICH THERE HAS BEEN NO SAFETY RECALL. A FAILURE LIKE THIS WITH NO MECHANICAL BACKUP FOR ENGINE THROTTLE CONTROL IS A SERIOUS SAFETY ISSUE. *TR

NHTSA ODI #10290423

91,000 miles · Oct 9, 2009
Engine And Engine Cooling

2005 FORD EXPEDITION - ENGINE DEFAULTS TO "LIMP HOME" MODE WHILE IN TRAFFIC. HAS OCCURRED TWICE SO FAR BUT HAVE BEEN ABLE TO NEGOTIATE GETTING OFF THE ROAD. VEHICLE HAS RESTARTED AFTER SITTING FEW MINUTES. *TR

NHTSA ODI #10286950

Official recalls

0

No recalls in this snapshot.

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