IllustrationMY TRUCK LOST ALL FORWARD GEARS EXCEPT FOR REVERSE OUT OF THE BLUE THE OTHER MORNING WHEN ATTEMPTING TO LEAVE HOME. VALVE BODY, SERVOS, SOLENOIDS, HAVE BEEN REPLACED AND STILL HAS NOT CORRECTED THE ISSUE. THE VEHICAL HAS LESS THEN 155000 MILES
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
Power Train complaints
44 reportsMY CAR AT TIMES WILL GIVE A HARD START. TURNING, BUT NOT FULLY TURNING OVER OR GIVES OFF A SOUND THAT I CAN ONLY DESCRIBE AS AN ELEPHANT TRUMPETING. WHEN IT DOES START AT TIMES IT WILL SHUT COMPLETELY OFF JUST AS FAST. IT HESITATES TO PICK UP ADEQUATE SPEED AND WILL STUMBLE OR JERK, AND WHEN PUT IN REVERSE IT WILL COMPLETELY STA…
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MY CAR AT TIMES WILL GIVE A HARD START. TURNING, BUT NOT FULLY TURNING OVER OR GIVES OFF A SOUND THAT I CAN ONLY DESCRIBE AS AN ELEPHANT TRUMPETING. WHEN IT DOES START AT TIMES IT WILL SHUT COMPLETELY OFF JUST AS FAST. IT HESITATES TO PICK UP ADEQUATE SPEED AND WILL STUMBLE OR JERK, AND WHEN PUT IN REVERSE IT WILL COMPLETELY STALL OUT. I'VE HAD A NEW BATTERY INSTALLED, AND THE SPARK PLUGS AND BOOTS HAVE BEEN CHANGED, BUT TO NO AVAIL.
I HAVE AN 05 EXPEDITION EDDIE BAUER EDITION AND THE TRUCK WAS SHUDDERING AND VIBRATING WHILE ON INCLINE OR DRIVING. IT ALSO WOULD HESITATE UPON ACCELERATION. THE NEXT DAY THE TRUCK WILL ONLY ROLL IN REVERSE IT WILL NOT DRIVE FORWARD AND THE "CHECK ELECTRONIC THROTTLE CONTROL" MESSAGE CONTINUES TO POP UP. DROVE IT AND ALL OF A SU…
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I HAVE AN 05 EXPEDITION EDDIE BAUER EDITION AND THE TRUCK WAS SHUDDERING AND VIBRATING WHILE ON INCLINE OR DRIVING. IT ALSO WOULD HESITATE UPON ACCELERATION. THE NEXT DAY THE TRUCK WILL ONLY ROLL IN REVERSE IT WILL NOT DRIVE FORWARD AND THE "CHECK ELECTRONIC THROTTLE CONTROL" MESSAGE CONTINUES TO POP UP. DROVE IT AND ALL OF A SUDDEN IT WOULDN'T SHIFT, AND ALL GAUGES WENT FLAT, TRUCK WAS STILL REVVING BUT GAUGES WERE AT ZERO AND THE TRUCK WOULDN'T MOVE. I WAS GOING 60 MPH. AND IT JUST STOPPED MOVING COMPLETELY. CANNOT DRIVE THE TRUCK.
TRANSMISSION BAD ,PAINT COME OUT SOME AREAS, REPLACE ALL THE SPARK PLUGS
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.
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
ACCELERATED ENGINE TO PASS, ENGINE COUGHED AND HEAVED. THE RPM CLIMBED BUT VEHICLE ACTED LIKE IT WAS DYING. CAR EVENTUALLY DIED. TURNED CAR OFF RE- STARTED IT. CHK ENGINE LIGHT CAME ON. ENGINE RAN ROUGH WANTED TO RAMP UP IN RPMS BUT STILL ACTED LIKE IT WAS GOING TO DIE. (THIS IS NOT THE FIRST TIME, IT IS VERY INTERMITTENT) THE L…
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ACCELERATED ENGINE TO PASS, ENGINE COUGHED AND HEAVED. THE RPM CLIMBED BUT VEHICLE ACTED LIKE IT WAS DYING. CAR EVENTUALLY DIED. TURNED CAR OFF RE- STARTED IT. CHK ENGINE LIGHT CAME ON. ENGINE RAN ROUGH WANTED TO RAMP UP IN RPMS BUT STILL ACTED LIKE IT WAS GOING TO DIE. (THIS IS NOT THE FIRST TIME, IT IS VERY INTERMITTENT) THE LAST TIME IT SEEMED SERIOUS AND CONTINUOUS THEY CHANGED THE TRANSMISSION. THE PROBLEM DID NOT LEAVE. I READ NUMEROUS POST ON THE WEB SITE AS THE PROBLEM CONTINUES TO COME BACK. NEVER SHOWING CODES. JUST RUNS LIKE CRAP. NUMEROUS IDENTICAL PROBLEMS ON THE INTERNET. BOUGHT A NEW MAF. NO HELP. REPLACED COIL PACKS NO HELP. CHECKED AND CLEANED VCT SOLENOIDS. NO HELP. REPLACED CAMSHAFT POSITION SENSOR. NO HELP. NO CHK ENG LIGHTS. WILL NOT EXCEED 3500 RPM. *TR
DRIVING ON HIGHWAY AT ABOUT 60 MPH CHANGING LANES AND A ODB MESSAGE APPEARS "CHECK ELECTRONIC THROTTLE CONTROL" AND THE CAR JUST SHUTS DOWN. IT WAS A LIFE THREATENING MOMENT FOR MY FAMILY AND I AS A TRUCK THAT WAS ON COMING FROM BEHIND WITH SPEED HAD TO SLAM ON THE BRAKES IN ORDER NOT TO COLLIDE WITH ME SINCE I HAD NO POWER TO A…
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DRIVING ON HIGHWAY AT ABOUT 60 MPH CHANGING LANES AND A ODB MESSAGE APPEARS "CHECK ELECTRONIC THROTTLE CONTROL" AND THE CAR JUST SHUTS DOWN. IT WAS A LIFE THREATENING MOMENT FOR MY FAMILY AND I AS A TRUCK THAT WAS ON COMING FROM BEHIND WITH SPEED HAD TO SLAM ON THE BRAKES IN ORDER NOT TO COLLIDE WITH ME SINCE I HAD NO POWER TO ACCELERATE. I WAS ONLY FORTUNATE THAT THE TRUCK HAD A CLEAR LANE TO CHANGE INTO ABRUPTLY. THE ELECTRONIC THROTTLE MESSAGE AFTER FURTHER RESEARCH IS A WIDE SPREAD KNOW ISSUE AMONG FORD CARS AND I AM LIVID AND VERY ANGRY THAT THE NHTSA HAS NOT ISSUED A RECALL ON THIS KNOW ISSUE AS IT IS PUBLIC KNOWLEDGE ONLINE. THIS NEEDS TO BE ADDRESSED IMMEDIATELY TO AVOID ANY POTENTIAL FUTURE TRAGEDIES. I HOPE FORD DOES NOT WANT BLOOD ON THERE HANDS! *TR
TL* THE CONTACT OWNS A 2005 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 20 MPH, THE VEHICLE WOULD NOT ACCELERATE. THE VEHICLE WAS TOWED TO AN INDEPENDENT MECHANIC FOR DIAGNOSIS. THE MECHANIC STATED THAT THE TRANSMISSION WOULD HAVE TO BE REPLACED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE VE…
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TL* THE CONTACT OWNS A 2005 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 20 MPH, THE VEHICLE WOULD NOT ACCELERATE. THE VEHICLE WAS TOWED TO AN INDEPENDENT MECHANIC FOR DIAGNOSIS. THE MECHANIC STATED THAT THE TRANSMISSION WOULD HAVE TO BE REPLACED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE VEHICLE WAS REPAIRED. THE APPROXIMATE FAILURE MILEAGE WAS 149,000. *TR
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
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