NHTSA owner reports · September 18, 2026 snapshot.
Power Train complaints
44 reportsClear category filter10,000 miles · Dec 1, 2012
Electrical SystemEnginePower Train
FIRST TIME IT OCCURRED I WAS TRAVELING TO WORK THE CAR STALLED WHILE DRIVING APPROX. 20 MPH AND THERE WAS NO CONTROL OF THE CAR - WAS ABLE TO MOVE TO SIDE OF ROAD AND RESTART. FAULT ON THE CONSOLE WAS "ELECTRONIC THROTTLE". HAS HAPPEN APPROX 4 MORE TIMES AT VARIOUS SPEEDS AND CONDITIONS WITH THREE DIFFERENT DRIVERS. NO PROBLE…
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FIRST TIME IT OCCURRED I WAS TRAVELING TO WORK THE CAR STALLED WHILE DRIVING APPROX. 20 MPH AND THERE WAS NO CONTROL OF THE CAR - WAS ABLE TO MOVE TO SIDE OF ROAD AND RESTART. FAULT ON THE CONSOLE WAS "ELECTRONIC THROTTLE". HAS HAPPEN APPROX 4 MORE TIMES AT VARIOUS SPEEDS AND CONDITIONS WITH THREE DIFFERENT DRIVERS. NO PROBLEM EVER FOUND BY DEALER. HAS HAPPENED AT HIGH SPEED ON THE FREEWAY COMPLETE LOSS OF STEERING AND POWER OCCURS MORE CONCERNING IT CAN HAPPEN AT ANY TIME WITHOUT WARNING. I FIND THIS TO BE EXTREMELY DANGEROUS AND A DEATH TRAP WAITING TO HAPPEN. THE LAST TIME IT OCCURRED WHEN BY TEENAGE DAUGHTER WAS DRIVING SHE WAS SCARED TO DEATH REFUSING TO DRIVE IT HOME. THIS REMINDED ME OF TOYOTA PRIUS SO I TOOK IT UPON MYSELF TO REPORT MY INCIDENTS. LOOKING AT THE INTERNET I NOW FIND IT OCCURS FREQUENTLY AND IT IS NOT AN ISOLATED CASE. *TR
NHTSA ODI #10486629
46,600 miles · Oct 5, 2012
EnginePower Train
I WAS DRIVING, WHEN I TRIED TO FURTHER ACCELERATE, THE CAR DID NOT RESPOND AND A WARNING " CHECK ELECTRONIC THROTTLE CONTROL". I PULLED OVER AND WAS ABLE TO RESTART THE CAR AND CONTINUE TO DRIVE AS NORMAL. THE INTERNET INDICATES THIS IS A COMMON PROBLEM IN 2005 EXPEDITIONS. THIS IS OBVIOUS A HIGHLY DANGEROUS SITUATION TO NO…
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I WAS DRIVING, WHEN I TRIED TO FURTHER ACCELERATE, THE CAR DID NOT RESPOND AND A WARNING " CHECK ELECTRONIC THROTTLE CONTROL". I PULLED OVER AND WAS ABLE TO RESTART THE CAR AND CONTINUE TO DRIVE AS NORMAL. THE INTERNET INDICATES THIS IS A COMMON PROBLEM IN 2005 EXPEDITIONS. THIS IS OBVIOUS A HIGHLY DANGEROUS SITUATION TO NOT BE ABLE TO ACCELERATE WHILE ALREADY DRIVING. *TR
NHTSA ODI #10478726
83,000 miles · Oct 1, 2012
Fuel/propulsion SystemPower TrainVehicle Speed Control
I HAVE A 2005 EXPEDITION AND HAVE HAD A ELECTRONIC THROTTLE CONTROL FAILURE ON IT TWICE IN THE LAST 10 MONTHS. BOTH CASES HAPPENED WHILE TURNING THROUGH A MAJOR INTERSECTION, THE ENGINE CONTINUED TO RUN, BUT THERE WAS NO CONNECTION BETWEEN THE GAS PEDAL AND THE THROTTLE (STEPPING ON THE GAS HAD NO EFFECT). LUCKILY I WAS ABLE T…
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I HAVE A 2005 EXPEDITION AND HAVE HAD A ELECTRONIC THROTTLE CONTROL FAILURE ON IT TWICE IN THE LAST 10 MONTHS. BOTH CASES HAPPENED WHILE TURNING THROUGH A MAJOR INTERSECTION, THE ENGINE CONTINUED TO RUN, BUT THERE WAS NO CONNECTION BETWEEN THE GAS PEDAL AND THE THROTTLE (STEPPING ON THE GAS HAD NO EFFECT). LUCKILY I WAS ABLE TO COAST THROUGH THE INTERSECTION AND ONTO THE SHOULDER WITHOUT GETTING HIT. THE FIRST OCCURRENCE WAS IN DEC 2011, AND IT JUST HAPPENED AGAIN THIS MORNING (1 OCT 2012), LUCKILY I WAS DRIVING AND SAFELY MANEUVERED OUT OF HARM'S WAY. IF IT HAD BEEN MY WIFE AND CHILDREN IN THE VEHICLE, OR IF IT HAD HAPPENED ON THE HIGHWAY, IT IS HIGHLY LIKELY THAT THE OUTCOME WOULD HAVE BEEN MUCH WORSE. THERE ARE MANY REPORTS OF THIS SAME FAILURE ON THE INTERNET. I WILL NOT LET MY WIFE AND CHILDREN RIDE IN THE VEHICLE TRIED TO HAVE FIXED AT THE DEALER IN DEC 2011 AND THEY HAD NO IDEA HOW TO FIX IT, JUST WANTED TO START REPLACING PARTS. CALLED THE DEALER AGAIN TODAY AND THEY HAD NO OTHER ANSWER. *TR
NHTSA ODI #10478146
120,000 miles · Jun 13, 2012
Power Train
A CLUNK/THUMP NOISE FROM THE REAR WHEN THE TRANSMISSION IS ENGAGED OR SHIFTED, DURING A CHANGE IN VEHICLE DIRECTION OR ON ACCELERATION. HAVE HAD MY TRANS REPLACED ONCE UNDER WARRANTY AND NOW ITS DOING THE SAME THING AGAIN. *TR
NHTSA ODI #10461642
102,000 miles · Jun 13, 2012
Electrical SystemEnginePower Train
WARNING LIGHT SAID ELECTRONIC THROTTLE CONTROL, THIS IS THE THIRD TIME I HAVE ALMOST HAD A MAJOR ACCIDENT AND FORD TELLS ME TO CALL THEM WHEN I HAVE AN ACCIDENT OR THE CODE SHOWS BACK UP. THEY ADMIT THAT THEY ARE AWARE OF THIS ISSUE BUT IT MUST FAIL COMPLETELY BEFORE IT CAN BE REPLACED UNDER WARRANTY OR RECALL. ALSO THE TRUCK C…
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WARNING LIGHT SAID ELECTRONIC THROTTLE CONTROL, THIS IS THE THIRD TIME I HAVE ALMOST HAD A MAJOR ACCIDENT AND FORD TELLS ME TO CALL THEM WHEN I HAVE AN ACCIDENT OR THE CODE SHOWS BACK UP. THEY ADMIT THAT THEY ARE AWARE OF THIS ISSUE BUT IT MUST FAIL COMPLETELY BEFORE IT CAN BE REPLACED UNDER WARRANTY OR RECALL. ALSO THE TRUCK CUTS OUT AT 60MPH AND JERKS UNTIL YOU SPEED UP. THEY ADVISED THEY ARE ALSO AWARE OF THIS PROBLEM AND COME BACK WHEN IT BREAKS DOWN. *TR
NHTSA ODI #10461641
84,328 miles · Feb 3, 2012
Power TrainVehicle Speed Control
I HAVE A 2005 FORD EXPEDITION WITH 84K MILES AND I WAS GOING 30 MPH WHEN I LOST THE GAS PEDAL(POWER) TO MY VEHICLE. WARNING LIGHT CAME ON AND THEN I PULLED TO SIDE OF ROAD. LUCKY I WAS NOT HIT FROM BEHIND DUE TO LOSING POWER TO THE ENGINE. TURNED VEHICLE OFF FOR A FEW MINUTES AND THEN TURNED BACK ON. NO WARNING LIGHT AND TRUCK R…
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I HAVE A 2005 FORD EXPEDITION WITH 84K MILES AND I WAS GOING 30 MPH WHEN I LOST THE GAS PEDAL(POWER) TO MY VEHICLE. WARNING LIGHT CAME ON AND THEN I PULLED TO SIDE OF ROAD. LUCKY I WAS NOT HIT FROM BEHIND DUE TO LOSING POWER TO THE ENGINE. TURNED VEHICLE OFF FOR A FEW MINUTES AND THEN TURNED BACK ON. NO WARNING LIGHT AND TRUCK RAN FINE. TOOK IT TO LOCAL FORD DEALER WHO FOR $98 TELLS ME I NEED TO SPEND ANOTHER $600 TO REPLACE THROTTLE BODY. AFTER A LONG DISCUSSION WITH SERVICE MANAGER I DECIDED TO DECLINE THE REPAIR UNTIL I CONTACT FORD AND NATIONAL HIGHWAY SAFETY BOARD. *KB
NHTSA ODI #10446600
129,000 miles · Dec 23, 2011
Power Train
TRAVELING IN A PARKING LOT CAR DIED AND SAID CHECK ELECTRIC THROTTLE CONTROL. WONT RUN OR CRANK. LEFT STUCK IN A PARKING LOT HAD TO GET TOWED HOME. *TR
NHTSA ODI #10441137
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
90,000 miles · Aug 15, 2011
Power TrainVehicle Speed Control
2005 FORD EXPEDITION EDDIE BAUER, 90,000 MILES. (VEHICLE MANUFACTURED IN 2004.) WHILE BEING DRIVEN AT HIGHWAY SPEED THROTTLE STUCK IN FULLY DEPRESSED POSITION AFTER BEING ENGAGED FOR A ROUTINE PASS OF ANOTHER VEHICLE. VEHICLE WAS NOTED TO ACCELERATE. ACCELERATOR PEDAL COULD NOT BE RETURNED TO NON-DEPRESSED STATE WHEN FORCE …
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2005 FORD EXPEDITION EDDIE BAUER, 90,000 MILES. (VEHICLE MANUFACTURED IN 2004.) WHILE BEING DRIVEN AT HIGHWAY SPEED THROTTLE STUCK IN FULLY DEPRESSED POSITION AFTER BEING ENGAGED FOR A ROUTINE PASS OF ANOTHER VEHICLE. VEHICLE WAS NOTED TO ACCELERATE. ACCELERATOR PEDAL COULD NOT BE RETURNED TO NON-DEPRESSED STATE WHEN FORCE APPLIED. BRAKES APPLIED FORCEFULLY, VEHICLE WAS UNABLE TO BE SLOWED OR BROUGHT TO A STOP. STRONG SMELL OF "BURNING" BRAKE PADS WAS NOTED. ATTEMPTED TO SHIFT VEHICLE INTO AUTOMATIC TRANSMISSION POSITION OF NEUTRAL. NO CHANGE IN ENGINE SPEED NOTED. TRANSMISSION THEN SHIFTED INTO REVERSE. VEHICLE WHEELS LOCKED UP AND VEHICLE SKIDDED APPROXIMATELY 100 - 150 FEET BEFORE COMING TO A STOP. ANTILOCK SYSTEM AND OTHER SYSTEMS DID NOT ACTIVATE. AFTER COMING TO A STOP, THROTTLE PEDAL WAS INSPECTED. NO INTERIOR INTERFERENCE FROM FLOOR MATS OR OTHER MATERIALS NOTED. OPERATOR IS 100% CERTAIN AS A RESULT OF "REAL-TIME" VISUAL CONFIRMATION, THAT ACCELERATOR AND BRAKE PEDALS WERE NOT MISTAKENLY ENGAGED OR DUALLY ENGAGED. CRUISE CONTROL WAS NOT ENGAGED. VEHICLE HAS BEEN SERVICED AND MAINTAINED REGULARLY AND WITH PRECISION AND DETAIL. VEHICLE WAS INSPECTED BY AN INDEPENDENT MECHANIC IMMEDIATELY POST THE INCIDENT. THROTTLE BODY FOUND TO BE FOULED AND DIRTY. INDEPENDENT MECHANIC IS REASONABLY CERTAIN THAT DIRTY THROTTLE BODY IS MOST LIKELY CAUSE OF THIS EVENT. INDEPENDENT MECHANIC HAS PERSONAL KNOWLEDGE AND EXPERIENCE OF SIMILAR THROTTLE BODY FAILURES PRODUCING SIMILAR EVENTS AS HAS BEEN DESCRIBED ABOVE. THIS VEHICLE HAS HAD OTHER PREMATURE FAILURES, INCLUDING (1) NEED FOR TRANSMISSION AND TRANSFER CASE TO BE REBUILT AT 28,000 MILES; (2) FAILURE OF POWER DRIVER'S SEAT TO MOVE ON ITS TRACK AT 25,000 MILES; (3) PREMATURE CAM PHASER FAILURE AND REBUILD AT APPROXIMATELY 35,000 MILES. *TR
NHTSA ODI #10419439
63,000 miles · Jun 16, 2011
Power Train
TL* THE CONTACT OWNS A 2005 FORD EXPEDITION. THE CONTACT STATED THAT THE VEHICLE STALLED AND RESTARTED INDEPENDENTLY WITHIN MINUTES. THE OVERDRIVE WARNING INDICATOR WAS ILLUMINATED AND THE ENGINE BEGAN TO EXHIBIT ABNORMALLY LOUD NOISES. IN ADDITION, THE VEHICLE WOULD NOT SHIFT GEARS. THE VEHICLE WAS TOWED TO THE DEALER WHO DIAG…
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TL* THE CONTACT OWNS A 2005 FORD EXPEDITION. THE CONTACT STATED THAT THE VEHICLE STALLED AND RESTARTED INDEPENDENTLY WITHIN MINUTES. THE OVERDRIVE WARNING INDICATOR WAS ILLUMINATED AND THE ENGINE BEGAN TO EXHIBIT ABNORMALLY LOUD NOISES. IN ADDITION, THE VEHICLE WOULD NOT SHIFT GEARS. THE VEHICLE WAS TOWED TO THE DEALER WHO DIAGNOSED THAT THE TRANSMISSION WAS DEFECTIVE AND NEEDED TO BE REPLACED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE WHO DID NOT OFFER ANY ASSISTANCE SINCE THE VEHICLE WAS OUT OF WARRANTY. THE VEHICLE WAS NOT REPAIRED. THE FAILURE AND CURRENT MILEAGE WAS 63,000.
NHTSA ODI #10407163
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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