NHTSA owner reports · September 18, 2026 snapshot.
Power Train complaints
44 reportsClear category filter100,000 miles · Jun 1, 2011
Electrical SystemPower Train
WE WIFE HAS A 2005 FORD EXPEDITION, IT IS USED MAINLY FOR HER TO HAUL OUR KIDS TO PRACTICE AND SCHOOL BACK AND FORTH. THE TRUCK IS CONSTANTLY DYING WHILE DRIVING IT. THE DISPLAY SHOWS CHECK ELECTRONIC THROTTLE CONTROL". THIS MORNING SHE WAS TAKING THE KIDS TO SCHOOL WHEN IT DIED WHILE GOING THROUGH AN INTERSECTION. I HAVE TALKED…
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WE WIFE HAS A 2005 FORD EXPEDITION, IT IS USED MAINLY FOR HER TO HAUL OUR KIDS TO PRACTICE AND SCHOOL BACK AND FORTH. THE TRUCK IS CONSTANTLY DYING WHILE DRIVING IT. THE DISPLAY SHOWS CHECK ELECTRONIC THROTTLE CONTROL". THIS MORNING SHE WAS TAKING THE KIDS TO SCHOOL WHEN IT DIED WHILE GOING THROUGH AN INTERSECTION. I HAVE TALKED TO SEVERAL DIFFERENT DEALERS WHO SAY THEY NEVER HEARD OF THIS PROBLEM, BUT CAN CHECK IT OUT FOR $$$$$$ YET I CAN SEARCH THE INTERNET AND FIND THE SAME PROBLEM HAPPENING TO THESE EXPEDITIONS. MY QUESTIONS IS WHY ISN'T FORD BEING RESPONSIBLE AND GETTING THESE RECALLED AND REPAIRED BEFORE SOMEONE IS KILLED IN THESE VEHICLES. CAN YOU IMAGINE DRIVING WITH YOUR LOVED ONES AND LOOSING FULL CONTROL OF YOUR VEHICLE AT ANYTIME.WE HAVE EXPERIENCED THE SHUTDOWN AT ALL SPEEDS. IT IS GETTING WORSE. WHERE IS THE RECALL FORD?? BEFORE SOMEONE IS KILLED.........UPDATE CHANGED OUT THE TPS QUESS WHAT DIDN'T FIX IT STILL DOING IT..WHAT NOW FORD?? *TR
NHTSA ODI #10404033
81,024 miles · May 16, 2011
Power Train
2005 FORD EXPEDITION HAS BEEN STALLING WITH NO WARNING WITH THE CHECK THROTTLE CONTROL LIGHT ON. WILL RESTART AFTER TURNING OFF. I HAVE REPLACED THE THROTTLE SENSOR TWICE AND HAS NOT HELPED. THIS PROBLEM IS VERY COMMON FOR THE 2005 EXPEDITION. FORD DEALER WILL NOT HELP,BUT OFFERS A $700. FIX THAT I UNDERSTAND DOES NOT ALWAYS HE…
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2005 FORD EXPEDITION HAS BEEN STALLING WITH NO WARNING WITH THE CHECK THROTTLE CONTROL LIGHT ON. WILL RESTART AFTER TURNING OFF. I HAVE REPLACED THE THROTTLE SENSOR TWICE AND HAS NOT HELPED. THIS PROBLEM IS VERY COMMON FOR THE 2005 EXPEDITION. FORD DEALER WILL NOT HELP,BUT OFFERS A $700. FIX THAT I UNDERSTAND DOES NOT ALWAYS HELP. *TR
NHTSA ODI #10401179
83,000 miles · Jan 25, 2011
Electrical SystemPower Train
I WAS DRIVING UP THE HIGHWAY WITH MY TWO KIDS IN MY CAR. I WAS TRAVELING ABOUT 40 MPH. ALL OF A SUDDEN I HEAR THE BEEP ON MY SYSTEM AND IT STATED THAT I NEEDED TO " CHECK ELECTRONIC THROTTLE CONTROL". I LAID OFF THE GAS AND WENT THRU A LIGHT WHEN I ATTEMPTED TO HIT THE GAS AGAIN I REALIZED I HAD NO POWER AT ALL AND I WAS COAST…
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I WAS DRIVING UP THE HIGHWAY WITH MY TWO KIDS IN MY CAR. I WAS TRAVELING ABOUT 40 MPH. ALL OF A SUDDEN I HEAR THE BEEP ON MY SYSTEM AND IT STATED THAT I NEEDED TO " CHECK ELECTRONIC THROTTLE CONTROL". I LAID OFF THE GAS AND WENT THRU A LIGHT WHEN I ATTEMPTED TO HIT THE GAS AGAIN I REALIZED I HAD NO POWER AT ALL AND I WAS COASTING. I GOT IN THE TURNING LANE AND HAD TO PULL IN FRONT OF A CAR JUST SO I WOULD NOT BE STUCK IN THE MIDDLE OF THE ROAD WHERE MY KIDS AND I WOULD HAVE BEEN IN AN ACCIDENT. I WAITED ABOUT 10 MINUTES AND THE VEHICLE FIRED UP. I WAS IN TEARS TRYING TO MAKE IT TO MY OFFICE BECAUSE I FELT LIKE IT MIGHT HAPPEN AGAIN. THE WHOLE MILE IT TOOK FOR ME TO GET THERE THE TRUCK FELT LIKE IT WAS GOING TO SHUT OFF AGAIN. IT FELT LIKE THE TRUCK DID NOT HAVE GAS AND WAS RIDING ON FUMES. IT WAS SHAKING AND MOVING SLOWING. I WILL NOT DRIVE IT LIKE THIS AND WILL PROBABLY TRADE IT IN NOW. I CANNOT DRIVE A VEHICLE THAT I DO NOT FEEL IS RELIABLE FOR ME AND MY KIDS. THIS IS THE FIRST TIME THAT THIS HAS HAPPENED AND THE TRUCK HAS 83K MILES ON IT. I ALSO HAD PROBLEMS WITH THE CATALYTIC CONVERTER AT 46K MILES. MY MECHANIC SAID THAT THE THROTTLE BODY COULD HAVE FAILED AS A RESULT OF THE CATALYTIC CONVERTER NOT WORKING PROPERLY. I MIGHT TRY TO FIX THE PROBLEM DEPENDING ON COSTS ASSOCIATED WITH IT OR MIGHT GET ANOTHER VEHICLE. *TR
NHTSA ODI #10378596
83,500 miles · Dec 16, 2010
Engine And Engine CoolingPower Train
2005 FORD EXPEDITION LIMITED ~83.5K MILES VEHICLE HAD BEEN DRIVEN ABOUT A HALF HOUR AND THE ENGINE STOPPED WITHOUT WARNING, UNABLE TO ACCELERATE, BRAKE OR STEER. COASTED TO SIDE OF ROAD, SHUT VEHICLE OFF, RESTARTED. TOOK TO DEALERSHIP, UNABLE TO REGISTER CODE HOWEVER I PROVIDED THEM WITH COMMENTS FROM ONLINE SITES POINTING TO TH…
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2005 FORD EXPEDITION LIMITED ~83.5K MILES VEHICLE HAD BEEN DRIVEN ABOUT A HALF HOUR AND THE ENGINE STOPPED WITHOUT WARNING, UNABLE TO ACCELERATE, BRAKE OR STEER. COASTED TO SIDE OF ROAD, SHUT VEHICLE OFF, RESTARTED. TOOK TO DEALERSHIP, UNABLE TO REGISTER CODE HOWEVER I PROVIDED THEM WITH COMMENTS FROM ONLINE SITES POINTING TO THROTTLE CONTROL BODY FAILURE CAUSING ENGINE TO GO INTO FAILSAFE MODE. DEALERSHIP'S FIRST INCLINATION WITHOUT ANY CODES IS TO REPLACE A FUEL SENSOR. DEALERSHIP REFUSED TO ADDRESS THROTTLE CONTROL BODY DESPITE MY SUGGESTION ALONG WITH OTHER VEHICLE OWNER'S INCIDENT REPORTS FROM ONLINE SITES. 8 DAYS LATER WHILE MY HUSBAND WAS DRIVING MYSELF AND FIVE CHILDREN, AFTER ABOUT A HALF HOUR OF DRIVING, HE FOUND HE WAS UNABLE TO ACCELERATE, LOOKED AT THE MESSAGE CENTER AND IT SAID CHECK ELECTRONIC THROTTLE CONTROL AT WHICH TIME HE PUT THE VEHICLE IN NEUTRAL AND WAS ABLE TO RESTART. DEALERSHIPS ARE NOT ADDRESSING THIS ISSUE BECAUSE THE ONBOARD COMPUTER OR SENSORS ARE NOT STORING THESE CODES, THE PROBLEM IS SO FAR INTERMITTENT. THIS PARTICULAR DEALERSHIP DESPITE MY RESEARCH WOULD NOT ADDRESS THE ISSUE. IT ALSO APPEARS FORD IS NOT ACKNOWLEDGING THIS EITHER. SO FAR, I HAVE FOUND ONE INSTANCE ONLINE WHERE THE OWNER OF A 2006 EXPEDITION WAS REIMBURSED FROM FORD FOR THE REPLACEMENT OF THEIR ELECTRONIC THROTTLE CONTROL BODY THEREBY ACKNOWLEDGING SOME SEMBLANCE OF RESPONSIBILITY. THIS NEWER THROTTLE CONTROL BODY IS DIFFERENT THAN THE ORIGINAL, IMPROVED. WHY IS THERE NOT A RECALL OR EVEN A TSB? HOW MANY REPORTS OF THERE OUT THERE, HOW MANY ACCIDENTS, INJURIES, POSSIBLY DEATHS MIGHT BE ATTRIBUTED TO THIS FAILURE? AFTER CONTACTING FORD, WE WILL HAVE THE THROTTLE CONTROL BODY REPLACED. ALSO, IT APPEARS, PEOPLE ARE BEING SUGGESTED TO REPLACE THE SENSOR FIRST ONLY TO HAVE THE PROBLEM OCCUR AGAIN - IT'S NOT THE SENSOR, IT'S THE ACTUAL PART. *TR
NHTSA ODI #10370941
62,000 miles · Oct 13, 2010
Power Train
2005 FORD EXPEDITION, TRANSMISSION PROBLEM .WHILE TRAVELING ON A HIGHWAY, THE O/D OFF LIGHT CAME ON. THEN LATER ON , THE CHECK ELECTRONIC THROTTLE POSITION . THE VEHICLE WENT INTO A LIMP HOME MODE. UNSAFE'WHEN I DID INVESTIGATE ,I NOTICED MY VEHICLE WAS LEAKING TRANSMISSION FLUID. THE SPOT WHERE IT WAS LEAKING FROM WAS …
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2005 FORD EXPEDITION, TRANSMISSION PROBLEM .WHILE TRAVELING ON A HIGHWAY, THE O/D OFF LIGHT CAME ON. THEN LATER ON , THE CHECK ELECTRONIC THROTTLE POSITION . THE VEHICLE WENT INTO A LIMP HOME MODE. UNSAFE'WHEN I DID INVESTIGATE ,I NOTICED MY VEHICLE WAS LEAKING TRANSMISSION FLUID. THE SPOT WHERE IT WAS LEAKING FROM WAS NEAR THE RADIATOR, THE TRANSMISSION LINES TO AND FROM THE RADIATOR AND THE EXTERNAL TRANS COOLER AND TRANSMISSION WERE CORRODED. MY REPAIR SHOP TRIED TO OBTAIN AFTERMARKET ONLY TO FIND THEY HAD TO BE SPECIAL ORDERED FROM FORD. WHILE DOING THAT ,FORD INFORMED HIM, THEY HAD SOME 15 KITS COMING IN, HOWEVER THEY WERE ALL ACCOUNTED FOR AND THE NEXT SET WOULD BE IN ANOTHER MONTH. APPARENTLY THERE IS SOMETHING FAULTY. AND DEFINITELY UNSAFE.. *TR
NHTSA ODI #10360333
47,000 miles · Jun 2, 2010
Power Train
DRIVING MY 2005 FORD EXPEDITION LIMITED IN THE MORNING. AFTER ABOUT 2 MILES THE CAR POWERED TO A CRAWL AND GAVE ENGINE FAIL SAFE MODE ALERT. PULLED TO SIDE. POWERED DOWN CAR AND THE RESTARTED WITHOUT INCIDENT. A WEEK LATER THE SAME THING HAPPENED AGAIN. THIS IS APPARENTLY A DEFECTIVE THROTTLE CONTROL UNIT. THIS DESCRIPTION…
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DRIVING MY 2005 FORD EXPEDITION LIMITED IN THE MORNING. AFTER ABOUT 2 MILES THE CAR POWERED TO A CRAWL AND GAVE ENGINE FAIL SAFE MODE ALERT. PULLED TO SIDE. POWERED DOWN CAR AND THE RESTARTED WITHOUT INCIDENT. A WEEK LATER THE SAME THING HAPPENED AGAIN. THIS IS APPARENTLY A DEFECTIVE THROTTLE CONTROL UNIT. THIS DESCRIPTION IS ALL OVER THE INTERNET AND IS A KNOWN SAFETY PROBLEM AS PEOPLE ARE REPORTING THAT IT HAS HAPPENED TO THEM ON THE FREEWAY. CAR IS UNSAFE TO DRIVE AND EVEN THOUGH THE PROBLEM IS WELL KNOWN, FORD COMPANY IS TAKING NO RESPONSIBILITY. ALL NHTSA HAS TO DO IS GOOGLE "ENGINE FAIL SAFE MODE" AND SEE THE NUMBER OF PROBLEMS THAT COME UP WITH SAME ISSUE. THIS IS DEFINITELY A WELL KNOWN SAFETY PROBLEM BUT YET THERE IS NO RECALL. DEALER SAYS THROTTLE CONTROL UNIT HAS TO BE REPLACED AT A COST OF $514.61 + TAX. THIS PROBLEM MAY ALSO HAVE TAKEN OUT MY AIR CONDITIONING. IT WENT OUT AT THE SAME TIME AS THE SECOND FAILURE, BUT DEALER (VISTA FORD IN OXNARD) IS SAYING THERE IS NO RELATIONSHIP. OTHERS HAVE REPORTED A/C SHUTTING DOWN WHEN ENGINE FAIL SAFE FAILURE OCCURRED. *TR
NHTSA ODI #10334316
90,000 miles · Apr 13, 2010
Power Train
2005 FORD EXPEDITION "ELECTRONIC THROTTLE CONTROL" LIGHT WILL COME ON AND THE ENGINE WILL STALL. THIS WILL HAPPEN AT ANY TIME, ANY SPEED AND WITHOUT WARNING. UNFORTUNATELY SOMEONE WILL HAVE TO BE SEVERELY INJURED BEFORE FORD TAKES A LOOK AT THIS. *TR
NHTSA ODI #10325452
72,200 miles · Feb 26, 2010
Power Train
FORD EXPEDITION 2005 TRANSMISSION FAIL, SUV HAS BEEN DRIVEN IN NORMAL WAY, WITH GOOD MAINTENANCE. TOO NEW TO FAIL. MY WARRANTY EXPIRED AND I KNOW MANY OWNERS HAVE THE SAME PROBLEM. SUDDENLY O/D DASH LED BLINKING AND AFTER 10 MINUTES ONLY REVERSE GEAR WORKS WELL, NOW I NEED TO PAY 2500.00 DLLS FOR REPAIR ON VEHICLE NOT PAID OFF…
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FORD EXPEDITION 2005 TRANSMISSION FAIL, SUV HAS BEEN DRIVEN IN NORMAL WAY, WITH GOOD MAINTENANCE. TOO NEW TO FAIL. MY WARRANTY EXPIRED AND I KNOW MANY OWNERS HAVE THE SAME PROBLEM. SUDDENLY O/D DASH LED BLINKING AND AFTER 10 MINUTES ONLY REVERSE GEAR WORKS WELL, NOW I NEED TO PAY 2500.00 DLLS FOR REPAIR ON VEHICLE NOT PAID OFF YET. *TR
NHTSA ODI #10314475
80,000 miles · Dec 23, 2009
Power Train
TRANSMISSION ON 2005 EXPEDITION IS SLIPPING. WHEN THE VEHICLE IS PLACED INTO DRIVE AND THE FOOT THROTTLE IS DEPRESSED THE VEHICLE HESITATES TO MOVE FORWARD, BUT THEN JERKS FORWARD. OTHER TIMES IT SEEMS LIKE IT DOESN'T WANT TO UPSHIFT WHEN DRIVING ON THE FREEWAY. I MUST ALSO STATE THAT THE PAINT ON THE TIP OF THE HOOD AND ON TH…
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TRANSMISSION ON 2005 EXPEDITION IS SLIPPING. WHEN THE VEHICLE IS PLACED INTO DRIVE AND THE FOOT THROTTLE IS DEPRESSED THE VEHICLE HESITATES TO MOVE FORWARD, BUT THEN JERKS FORWARD. OTHER TIMES IT SEEMS LIKE IT DOESN'T WANT TO UPSHIFT WHEN DRIVING ON THE FREEWAY. I MUST ALSO STATE THAT THE PAINT ON THE TIP OF THE HOOD AND ON THE TAILGATE ARE STARTING TO BUBBLE /BLISTER, THE VEHICLE IS ONLY 5 YEARS OLD AND THE PAINT IS CARED FOR THROUGH POLISHING AND WAXING TWICE A YEAR. *TR
NHTSA ODI #10296852
51,195 miles · Oct 6, 2009
Power Train
TL*THE CONTACT OWNS A 2005 FORD EXPEDITION. WHEN HE ATTEMPTED TO DRIVE THE FAIL SAFE MODE WARNING LIGHT ILLUMINATED ON THE INSTRUMENT CONTROL PANEL, AND THEN THE VEHICLE STALLED. THE THROTTLE ALSO DISENGAGED, WHICH CAUSED THE VEHICLE TO DRIVE IN NEUTRAL GEAR. HE USUALLY HAS TO RESTART THE VEHICLE TO RESUME NORMAL OPERATION. NO …
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TL*THE CONTACT OWNS A 2005 FORD EXPEDITION. WHEN HE ATTEMPTED TO DRIVE THE FAIL SAFE MODE WARNING LIGHT ILLUMINATED ON THE INSTRUMENT CONTROL PANEL, AND THEN THE VEHICLE STALLED. THE THROTTLE ALSO DISENGAGED, WHICH CAUSED THE VEHICLE TO DRIVE IN NEUTRAL GEAR. HE USUALLY HAS TO RESTART THE VEHICLE TO RESUME NORMAL OPERATION. NO REPAIRS WERE MADE. THE FAILURE MILEAGE WAS 51,195. THE CURRENT MILEAGE WAS 61,000.
NHTSA ODI #10286400
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