IllustrationI WAS DRIVING 55MPH ON HIGHWAY, WHEN ALL OF A SUDDEN THERE WAS NO POWER TO GAS PEDAL. THE CHECK ELECTRONIC THROTTLE CONTROL LIGHT FLASHED, I PULLED OVER THREE LANES TO SIDE OF ROAD. I SAT THERE TRYING TO START VEHICLE CONTINUOUSLY, FINALLY AFTER 10 MINUTES IT STARTED. *TR
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 →How this year compares
Owner complaints by model year
Compare all Expedition years →Counts vary with age, sales and reporting. They are not failure rates.
What owners reported most
All reported categories
Tap a category to read its complaints. One report may name several components.
When problems were reported
Mileage at the reported incident
250–25K
4025–50K
7950–75K
6275–100K
60100–150K
23150K+
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
Fuel System, Gasoline complaints
36 reports2005 FORD EXPEDITION WITHOUT WARNING STALLED WHILE MAKING A RIGHT HAND TURN AT AN INTERSECTION. VEHICLE TAKEN TO DEALERSHIP AND INFORMED ELECTRONIC THROTTLE BODY NEEDED TO BE REPLACED. VEHICLE ONLY HAS 60,000 MILES. INFORMED BY DEALERSHIP REASONS FOR DEFECT UNKNOW. HOWEVER, WE WERE STILL RESPONSIBLE FOR ALL REPAIR COSTS. REV…
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2005 FORD EXPEDITION WITHOUT WARNING STALLED WHILE MAKING A RIGHT HAND TURN AT AN INTERSECTION. VEHICLE TAKEN TO DEALERSHIP AND INFORMED ELECTRONIC THROTTLE BODY NEEDED TO BE REPLACED. VEHICLE ONLY HAS 60,000 MILES. INFORMED BY DEALERSHIP REASONS FOR DEFECT UNKNOW. HOWEVER, WE WERE STILL RESPONSIBLE FOR ALL REPAIR COSTS. REVIEW OF INTERNET INDICATES SEVERAL FORD CUSTOMERS HAVE REPORTED SAME PROBLEM WITH EXACT YEAR AND MAKE OF VEHICLE. *TR
I HAVE A 2005 FORD EXPEDITION LIMITED. MY COMPLAINT IS THE THROTTLE BODY FAILURE. WHEN DRIVING DOWN THE ROAD, THE ENGINE WILL SHUT DOWN AND YOU LOOSE ALL POWER TO THE VEHICLE. I HAVE HAD THIS HAPPEN AT SPEEDS OF 55+ MPH AS WELL AS SPEEDS OF APPROX LESS THAN 10 MPH, SUCH AS WHILE IN A PARKING LOT. THIS PROBLEM STARTED IN THE …
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I HAVE A 2005 FORD EXPEDITION LIMITED. MY COMPLAINT IS THE THROTTLE BODY FAILURE. WHEN DRIVING DOWN THE ROAD, THE ENGINE WILL SHUT DOWN AND YOU LOOSE ALL POWER TO THE VEHICLE. I HAVE HAD THIS HAPPEN AT SPEEDS OF 55+ MPH AS WELL AS SPEEDS OF APPROX LESS THAN 10 MPH, SUCH AS WHILE IN A PARKING LOT. THIS PROBLEM STARTED IN THE SUMMER OF 2009, AND HAS HAPPENED EVERY MONTH SINCE, SOMETIMES SEVERAL TIMES DURING THE MONTH. WE TOOK THE VEHICLE TO HAVE IT TESTED AND WERE TOLD IT WAS A TPS SENSOR. THAT HAS BEEN REPLACED ($75.00) BUT THE PROBLEM IS STILL HAPPENING. I HAVE DONE SOME RESEARCH ON THIS AND IT IS AN ONGOING PROBLEM WITH THE 2005 EXPEDITIONS. I PERSONALLY KNOW OF 2 OTHER PEOPLE THAT HAVE HAD THE SAME PROBLEM AND HAVE HAD TO HAVE THE ENTIRE THROTTLE BODY REPLACED, ONE OF WHICH HAS HAD IT REPLACED TWICE NOW. THIS IS A HUGE CONCERN SINCE YOU DO LOOSE ALL POWER AND HAVE TO TRY TO COAST TO THE SIDE OF THE ROAD, WHILE TRYING TO AVOID BEING HIT BY OTHER VEHICLES ON THE ROAD. MY CONCERN IS THAT WHEN THIS HAPPENS, THE RESULT WILL BE A ACCIDENT WHILE TRYING TO GET THE VEHICLE TO THE SIDE OF THE ROAD. THE REPAIR COST FOR JUST THE PARTS IS $600.00, BUT THIS DOES NOT INCLUDE THE LABOR. FORD NEEDS TO RECALL THIS PART BEFORE SOMEONE DOES DIE OR IS SERIOUSLY INJURED, AS IT IS A HUGE SAFETY CONCERN. FORD AND THEIR DEALERS ARE AWARE OF THE PROBLEM, YET THE ONLY RESOLUTION IS TO HAVE THE CONSUMER PAY FOR THE REPAIRS. I AM AFRAID TO DRIVE MY VEHICLE NOW BECAUSE OF THIS PROBLEM. I DO NOT HAVE THE OLD TPS SENSOR, BUT THE VEHICLE IS STILL DOING THIS AND DO STILL HAVE THE THROTTLE BODY THAT IS BAD ON THE VEHICLE FOR INSPECTION. WHEN THIS HAPPENS, THE INFORMATION CENTER IN THE DASH TELLS YOU TO "CHECK ELECTRONIC THROTTLE CABLE". *TR
2005 FORD EXPEDITION 78,000 MILES. IN THE LAST FEW MONTHS THE CAR AT TIMES HAS FELT AS THOUGH THERE IS LITTLE TO NO ACCELERATION, ALMOST LIKE THE CAR IS IN NEUTRAL. TODAY MY CAR STALLED AND I WAS ABLE TO DRIFT TO THE SIDE OF THE ROAD. THE "CHECK ELECTRONIC THROTTLE" LIGHT CAME ON. THE CAR IS AT THE DEALER NOW, WITH A $600+ R…
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2005 FORD EXPEDITION 78,000 MILES. IN THE LAST FEW MONTHS THE CAR AT TIMES HAS FELT AS THOUGH THERE IS LITTLE TO NO ACCELERATION, ALMOST LIKE THE CAR IS IN NEUTRAL. TODAY MY CAR STALLED AND I WAS ABLE TO DRIFT TO THE SIDE OF THE ROAD. THE "CHECK ELECTRONIC THROTTLE" LIGHT CAME ON. THE CAR IS AT THE DEALER NOW, WITH A $600+ REPAIR BILL. SEEMS THERE SHOULD BE A CHECK FOR SUCH SYSTEMS. WHAT WOULD HAVE HAPPENED HAD I BEEN ON A BUSIER STREET OR FREEWAY. *TR
DRIVING NORMALLY ON THE HIGHWAY, VEHICLE STALLS AT REGULAR SPEED, LOSS OF ALL POWER, COAST TO A STOP ON THE SHOULDER OF THE HIGHWAY. *TR
I HAVE A 2005 EXPEDITION AND IT JUST CUT OFF! I WAS DRIVING ABOUT 40 MILES PER HOUR AND IT JUST CUT OFF WHILE I WAS PRESSING ON THE GAS. I HAD TO COAST OFF THE SIDE OF THE ROAD. I ALMOST GOT IN AN ACCIDENT! A WARNING ALERT SAID CHECK ELECTRONIC THROTTLE AND I COULD NOT MOVE IT AND JUST STOP AND DIED. I WAITED ABOUT 5 MINUT…
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I HAVE A 2005 EXPEDITION AND IT JUST CUT OFF! I WAS DRIVING ABOUT 40 MILES PER HOUR AND IT JUST CUT OFF WHILE I WAS PRESSING ON THE GAS. I HAD TO COAST OFF THE SIDE OF THE ROAD. I ALMOST GOT IN AN ACCIDENT! A WARNING ALERT SAID CHECK ELECTRONIC THROTTLE AND I COULD NOT MOVE IT AND JUST STOP AND DIED. I WAITED ABOUT 5 MINUTES AND TRIED TO START MY CAR AGAIN AND IT STARTED. THE ENGINE LIGHT WAS ON AND TOOK IT TO AUTOZONE AND THE DIAGNOSTIC SAYS THAT THE THROTTLE IS STUCK. THIS HAPPENED TO ME LAST YEAR AROUND ABOUT THE SAME TIME AND JUST WENT AWAY. THE YEAR BEFORE I BROUGHT THE CAR FROM THE DEALERSHIP AND IT DID THIS TO ME 3 DAYS AFTER I BOUGHT IT. I TOOK IT BACK TO GET IT REPAIRED AND THEY FIXED IT NO CHARGE. NOW THEY ARE TRYING TO CHARGE ME. IT COST 700 DOLLARS EVERYTIME THIS PART GOES OUT. WHY SHOULD I HAVE TO KEEP GETTING THIS REPAIRED? THERE SHOULD BE A RECALL ON THIS VEHICLE (ELECTRIC THROTTLE). THERE ARE PLENTY OF COMPLAINTS ABOUT THIS PART. PLEASE INVESTIGATE AND SEE FOR YOURSELVES. IF YOU DO RESEARCH ON HOW MAY TIME PEOPLE HAVE TO GO FOR REPEAT REPAIR, I AM SURE IT WOULD BE OFF THE CHARTS. IT HAS A POOR DESIGN. IT COULD POTENTIALLY GET SOME KILLED, IF NOT ALREADY. I WAS IN THE CAR WITH MY CHILDREN AND I WAS SCARED! *TR
2005 FORD EXPEDITION EB FUEL PUMP BROKE AT 65000 MILES. AUTO BOUGHT BRAND NEW AND IN EXCELLENT CONDITION. FORD DEALER AND FORD REP CANNOT LOCATE THE REPLACEMENT PUMP.. SAID IT WILL BE LATE FEBRUARY IF I AM LUCKY. THIS IS MY MAIN MODE OF TRANSPORTATION!! *TR
2005 FORD EXPEDITION WILL DIE WHILE DRIVING AND A WRENCH LIGHT APPEARS ON THE DASH. THIS HAS HAPPENED MORE THAN 5 TIMES IN THE LAST MONTH. THE DEALER HAS STATED THAT THERE ARE THOUSANDS OF THESE OCCURRENCES WITH THE THROTTLE BODY NEEDING TO BE REPLACED AT AN $800 OWNERS EXPENSE. THE EXPEDITION IS NOT THE ONLY MODEL HAVING THI…
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2005 FORD EXPEDITION WILL DIE WHILE DRIVING AND A WRENCH LIGHT APPEARS ON THE DASH. THIS HAS HAPPENED MORE THAN 5 TIMES IN THE LAST MONTH. THE DEALER HAS STATED THAT THERE ARE THOUSANDS OF THESE OCCURRENCES WITH THE THROTTLE BODY NEEDING TO BE REPLACED AT AN $800 OWNERS EXPENSE. THE EXPEDITION IS NOT THE ONLY MODEL HAVING THIS PROBLEM. *TR
ON 1/23 MY WIFE (5 MONTHS PREGNANT) WAS DRIVING ALONE WITH MY 2 YEAR OLD SON THROUGH THE CA DESERT ON HER WAY TO PHOENIX, AZ. IN OUR 2005 FORD EXPEDITION WITH ONLY 35K MILES ON IT. ABOUT 20 MILES FROM BLYTHE, CA THREE FUEL INJECTORS FAILED. LUCKILY SHE FOUND A FORD DEALERSHIP IN BLYTHE THAT WAS OPEN ON THAT FRIDAY AND ABLE TO RE…
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ON 1/23 MY WIFE (5 MONTHS PREGNANT) WAS DRIVING ALONE WITH MY 2 YEAR OLD SON THROUGH THE CA DESERT ON HER WAY TO PHOENIX, AZ. IN OUR 2005 FORD EXPEDITION WITH ONLY 35K MILES ON IT. ABOUT 20 MILES FROM BLYTHE, CA THREE FUEL INJECTORS FAILED. LUCKILY SHE FOUND A FORD DEALERSHIP IN BLYTHE THAT WAS OPEN ON THAT FRIDAY AND ABLE TO REPLACE THEM. UPON ARRIVAL IN PHOENIX, ANOTHER DEALER DETERMINED THAT THE CATALYTIC CONVERTER WAS DESTROYED AS A RESULT. I WOULD LIKE FORD TO REPLACE THE REMAINING 5 FUEL INJECTORS BEFORE THEY FAIL. WHAT KIND OF FORD POLICY IS IT TO EXTEND THE WARRANTY TO 120K MILES ON A KNOWN DEFECT AND WAIT FOR DISASTER? IT IS INSANE TO NOT BE ABLE TO RELY ON OUR CAR FOR LONG DISTANCE TRAVEL AND ALWAYS WORRY ABOUT THIS INCIDENT REPEATING. THE COST OF REPLACING THE CATALYTIC CONVERTER AND RESULTING POLLUTION SHOULD ALSO BE A CONSIDERATION TO FORD? FYI: THE INJECTORS FROZE IN THE OPEN POSITION AND FLOODED THE ENGINE AND EXHAUST SYSTEM WITH FUEL I.E. FIRE! *TR
I WAS DRIVING 60MPH DOWN THE HIGHWAY AND THE DASH LIT UP WITH "CHECK ELECTRONIC FUEL CONTROL." I WAS ABLE TO GET THE VEHICLE TO THE SIDE OF THE ROAD AS THE ENGINE TURNED ITSELF OFF, NO POWER STEERING, AND LIMITED BRAKING ABILITY. AFTER A FEW MINUTES IT RESTARTED AND I WAS ABLE TO LIMP IT BACK HOME AND I PLAN ON TAKING INTO THE…
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I WAS DRIVING 60MPH DOWN THE HIGHWAY AND THE DASH LIT UP WITH "CHECK ELECTRONIC FUEL CONTROL." I WAS ABLE TO GET THE VEHICLE TO THE SIDE OF THE ROAD AS THE ENGINE TURNED ITSELF OFF, NO POWER STEERING, AND LIMITED BRAKING ABILITY. AFTER A FEW MINUTES IT RESTARTED AND I WAS ABLE TO LIMP IT BACK HOME AND I PLAN ON TAKING INTO THE LOCAL FORD DEALERSHIP IN THE MORNING. *TR
Official recalls
0No 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
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