NHTSA owner reports · September 18, 2026 snapshot.
Power Train complaints
44 reportsClear category filter38,000 miles · Jun 2, 2009
Power Train
WHILE DRIVING WITH A SMALL CHILD IN THE CAR - LESS THAN 15MPH NEAR A RESIDENTIAL AREA - MY 2005 FORD EXPEDITION LTD SUDDENLY FLASHED AN ERROR MESSAGE "CHECK ELECTRONIC THROTTLE CONTROL" AND IMMEDIATELY LOST ACCELERATION, BRAKING AND STEERING. I WAS ABLE TO VEER THE VEHICLE TO THE SIDE OF THE ROAD WITHOUT CAUSING AN ACCIDENT. I…
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WHILE DRIVING WITH A SMALL CHILD IN THE CAR - LESS THAN 15MPH NEAR A RESIDENTIAL AREA - MY 2005 FORD EXPEDITION LTD SUDDENLY FLASHED AN ERROR MESSAGE "CHECK ELECTRONIC THROTTLE CONTROL" AND IMMEDIATELY LOST ACCELERATION, BRAKING AND STEERING. I WAS ABLE TO VEER THE VEHICLE TO THE SIDE OF THE ROAD WITHOUT CAUSING AN ACCIDENT. I USED THE EMERGENCY BRAKE TO STOP THE VEHICLE AT WHICH TIME I MANUALLY TURNED OFF THE IGNITION. WAITED A FEW MOMENTS, AND MANAGED TO GET THE VEHICLE STARTED AND RUNNING AGAIN. THERE WAS ABSOLUTELY NO WARNING AND THE VEHICLE GIVES YOU NO OPPORTUNITY TO GET THE VEHICLE PULLED OVER SAFELY BEFORE DISENGAGING. THIS APPEARS TO BE A VERY SERIOUS AND DANGEROUS SUDDEN MECHANICAL FAILURE. *TR
NHTSA ODI #10272672
63,700 miles · Apr 20, 2009
Power Train
MY 05 FORD EXPEDITION WAS RECENTLY IN THE SHOP SEVERAL MONTHS BACK FOR ELECTRONIC THROTTLE ISSUES. TONIGHT THE CHECK ELECTRONIC THROTTLE LIGHT CAME ON AND CAUSED A TOTAL LOSS OF ACCELERATION. I PUT MY HAZARDS ON AND COASTED TO THE SIDE OF THE ROAD. AFTER TURNING OFF MY ENGINE AND RESTARTING MY VEHICLE RUNS LIKE NORMAL AGAIN. LUC…
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MY 05 FORD EXPEDITION WAS RECENTLY IN THE SHOP SEVERAL MONTHS BACK FOR ELECTRONIC THROTTLE ISSUES. TONIGHT THE CHECK ELECTRONIC THROTTLE LIGHT CAME ON AND CAUSED A TOTAL LOSS OF ACCELERATION. I PUT MY HAZARDS ON AND COASTED TO THE SIDE OF THE ROAD. AFTER TURNING OFF MY ENGINE AND RESTARTING MY VEHICLE RUNS LIKE NORMAL AGAIN. LUCKILY IT WAS VERY LATE AT NIGHT AND NO OTHER CARS WERE AROUND. THIS IS POTENTIALLY VERY DANGEROUS IF IT OCCURS IN FAST MOVING TRAFFIC. I HAVE RESEARCHED THIS ISSUE AND SEE COUNTLESS POSTS ON INTERNET FORUMS FROM 05 FORD EXPEDITION OWNERS DETAILING MY EXACT ISSUE AND TEMPORARY SOLUTION. WHEN IS THIS GOING TO BE OFFICIALLY ACKNOWLEDGED BY FORD AS A SERIOUS DEFECT AND RECALLED? *TR
NHTSA ODI #10266042
60,400 miles · Apr 11, 2009
Power Train
2005 FORD EXPEDITION WAS STOPPED AT STOP SIGN. "CHECK ELECTRONIC THROTTLE CONTROL" MESSAGE WAS DISPLAYED ON MESSAGE CENTER, ALONG WITH AN ANNUNCIATING "DING". ENGINE CONTINUED TO RUN, BUT ACCELERATOR PEDAL WAS COMPLETELY DEAD. SHUT OFF IGNITION AND RESTARTED VEHICLE, AND ACCELERATOR CONTROL RETURNED TO NORMAL. THERE WAS ONE OCCU…
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2005 FORD EXPEDITION WAS STOPPED AT STOP SIGN. "CHECK ELECTRONIC THROTTLE CONTROL" MESSAGE WAS DISPLAYED ON MESSAGE CENTER, ALONG WITH AN ANNUNCIATING "DING". ENGINE CONTINUED TO RUN, BUT ACCELERATOR PEDAL WAS COMPLETELY DEAD. SHUT OFF IGNITION AND RESTARTED VEHICLE, AND ACCELERATOR CONTROL RETURNED TO NORMAL. THERE WAS ONE OCCURRENCE SO FAR. *TR
NHTSA ODI #10265001
59,991 miles · Apr 7, 2009
Power Train
TL*THE CONTACT OWNS A 2005 FORD EXPEDITION. WHILE DRIVING APPROXIMATELY 10 MPH ON NORMAL ROAD CONDITIONS, THERE WAS NO RESPONSE WHEN THE ACCELERATOR PEDAL WAS DEPRESSED. AN UNKNOWN WARNING INDICATOR ILLUMINATED ON THE INSTRUMENT PANEL INTERMITTENTLY. ROADSIDE ASSISTANCE WAS CALLED TO THE SCENE AND THE VEHICLE WAS TOWED TO AN …
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TL*THE CONTACT OWNS A 2005 FORD EXPEDITION. WHILE DRIVING APPROXIMATELY 10 MPH ON NORMAL ROAD CONDITIONS, THERE WAS NO RESPONSE WHEN THE ACCELERATOR PEDAL WAS DEPRESSED. AN UNKNOWN WARNING INDICATOR ILLUMINATED ON THE INSTRUMENT PANEL INTERMITTENTLY. ROADSIDE ASSISTANCE WAS CALLED TO THE SCENE AND THE VEHICLE WAS TOWED TO AN AUTHORIZED DEALER FOR INSPECTION. THE TECHNICIAN STATED THAT THE TRANSMISSION FAILED. THE DEALER REPLACED THE AUTOMATIC TRANSMISSION. THE FAILURE MILEAGE WAS 59,991 AND CURRENT MILEAGE IS 62,000. UPDATED 05/06/09. *LJ UPATED 05/07/09.*JB
NHTSA ODI #10264350
63,130 miles · Dec 23, 2008
Power TrainVehicle Speed Control
"CHECK ELECTRONIC THROTTLE" MESSAGE APPEARED AND ACCELERATOR PEDAL BECAME INOPERATIVE. THIS IS THE SECOND TIME THIS HAS OCCURRED. SHIFTED VEHICLE INTO NEUTRAL, RESTARTED ENGINE WHILE ROLLING ALONG AND ERROR WAS CORRECTED. *TR
NHTSA ODI #10252614
63,000 miles · Dec 23, 2008
Power TrainVehicle Speed Control
"CHECK ELECTRONIC THROTTLE" MESSAGE APPEARED AND ACCELERATOR PEDAL BECAME UNRESPONSIVE IN TRAFFIC. PULLED OVER, RESTARTED ENGINE AND ISSUE CORRECTED ITSELF. *TR
NHTSA ODI #10252613
16,000 miles · Jun 26, 2008
Engine And Engine CoolingPower Train
TL*THE CONTACT OWNS A 2005 FORD EXPEDITION. THE CONTACT STATED THAT THE VEHICLE STALLS AND CONSTANTLY SHUTS OFF AT VARIOUS SPEEDS. THE VEHICLE WAS TAKEN TO THE DEALER ON EIGHT OCCASIONS FOR THE FAILURES. IN JANUARY OF 2008, THE DIAGNOSTIC INDICATED THAT THE THROTTLE BODY WAS THE CAUSE OF THE FAILURE AND IT WAS REPLACED. THE …
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TL*THE CONTACT OWNS A 2005 FORD EXPEDITION. THE CONTACT STATED THAT THE VEHICLE STALLS AND CONSTANTLY SHUTS OFF AT VARIOUS SPEEDS. THE VEHICLE WAS TAKEN TO THE DEALER ON EIGHT OCCASIONS FOR THE FAILURES. IN JANUARY OF 2008, THE DIAGNOSTIC INDICATED THAT THE THROTTLE BODY WAS THE CAUSE OF THE FAILURE AND IT WAS REPLACED. THE MOST RECENT FAILURE OCCURRED ON JUNE 1, 2008 WHILE DRIVING 60 MPH. THE VEHICLE WAS TOWED TO THE DEALER AND THEY STATED THAT THE TRANSMISSION FAILED. THE DEALER REPLACED THE TRANSMISSION. THE CONTACT SPENT $2,400 TO REPAIR THE VEHICLE THAT WAS PURCHASED NEW IN 2005. THE FAILURE MILEAGE WAS 16,000 AND CURRENT MILEAGE WAS 39,000.
NHTSA ODI #10232367
17,275 miles · May 16, 2008
Power Train
TL*THE CONTACT OWNS A 2005 FORD EXPEDITION. WHEN THE CONTACT STARTS THE VEHICLE, THE RPM'S INCREASED TO OVER 5,000 WHILE IT WAS IN GEAR AND WITH THE BRAKE PEDAL DEPRESSED. WHEN THE VEHICLE WAS PLACED INTO NEUTRAL, THE FAILURE CEASED AND THE VEHICLE DROVE NORMALLY. THE FAILURE WAS INTERMITTENT AND THE CONTACT HAS NOT BEEN IN A…
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TL*THE CONTACT OWNS A 2005 FORD EXPEDITION. WHEN THE CONTACT STARTS THE VEHICLE, THE RPM'S INCREASED TO OVER 5,000 WHILE IT WAS IN GEAR AND WITH THE BRAKE PEDAL DEPRESSED. WHEN THE VEHICLE WAS PLACED INTO NEUTRAL, THE FAILURE CEASED AND THE VEHICLE DROVE NORMALLY. THE FAILURE WAS INTERMITTENT AND THE CONTACT HAS NOT BEEN IN ANY CRASHES. THE VEHICLE HAS BEEN DIAGNOSED BY THE DEALER SEVERAL TIMES, BUT THE FAILURE CONTINUES. THE CURRENT MILEAGE WAS 33,000 AND FAILURE MILEAGE WAS 17,275.
NHTSA ODI #10227989
12,000 miles · Jan 30, 2008
Power TrainCrash
TL*THE CONTACT OWNS A 2005 FORD EXPEDITION. WHILE DRIVING 5 MPH, THE VEHICLE SLID INTO A DITCH. THE REAR DRIVER'S SIDE LIGHTS AND BUMPER WERE DAMAGED. THE DEALER STATED THAT THE VEHICLE WAS SUPPOSED TO COME EQUIPPED WITH FOUR WHEEL DRIVE, BUT DID NOT. THE MANUFACTURER PAID TO INSTALL THE FOUR WHEEL DRIVE FEATURE IN DECEMBER …
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TL*THE CONTACT OWNS A 2005 FORD EXPEDITION. WHILE DRIVING 5 MPH, THE VEHICLE SLID INTO A DITCH. THE REAR DRIVER'S SIDE LIGHTS AND BUMPER WERE DAMAGED. THE DEALER STATED THAT THE VEHICLE WAS SUPPOSED TO COME EQUIPPED WITH FOUR WHEEL DRIVE, BUT DID NOT. THE MANUFACTURER PAID TO INSTALL THE FOUR WHEEL DRIVE FEATURE IN DECEMBER OF 2006. ON DECEMBER 1, 2007, THE VEHICLE SLID OUT OF THE DRIVEWAY INTO THE MIDDLE OF THE STREET. IN JANUARY OF 2008, THE VEHICLE WAS TAKEN TO THE DEALER AND THEY REINSTALLED THE FOUR WHEEL DRIVE. THE CONTACT RETRIEVED THE VEHICLE ON JANUARY 10, 2008 AND THE FOUR WHEEL DRIVE FAILED AGAIN SEVEN DAYS LATER. THE CURRENT MILEAGE WAS 33,900 AND FAILURE MILEAGE WAS 12,000. UPDATED 3/4/08 *CN THE DEALER HAS SINCE FIXED THE 4-WHEEL DRIVE.
NHTSA ODI #10216518
49,000 miles · May 17, 2006
Power TrainCrash
DT*: THE CONTACT STATED WHILE THE VEHICLE WAS PARKED ON A SLIGHT INCLINE IT JUMPED OUT OF PARK AND ROLLED DOWN A HILL HITTING A TREE. UPON INSPECTING THE VEHICLE AFTER THE CRASH, THE GEAR INDICATOR WAS IN THE REVERSE POSITION. THERE WAS A POLICE REPORT FILED AT THE SCENE. THE VEHICLE WAS EXTENSIVELY DAMAGED HOWEVER, NONE OF T…
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DT*: THE CONTACT STATED WHILE THE VEHICLE WAS PARKED ON A SLIGHT INCLINE IT JUMPED OUT OF PARK AND ROLLED DOWN A HILL HITTING A TREE. UPON INSPECTING THE VEHICLE AFTER THE CRASH, THE GEAR INDICATOR WAS IN THE REVERSE POSITION. THERE WAS A POLICE REPORT FILED AT THE SCENE. THE VEHICLE WAS EXTENSIVELY DAMAGED HOWEVER, NONE OF THE AIR BAGS DEPLOYED. THE DEALERSHIP AND THE INSURANCE COMPANY HAVE BEEN INFORMED.
NHTSA ODI #10157698
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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