WAS DRIVING AND EXPERIENCED COMPLETE BRAKE FAILURE, NO WARNING, WENT TO STOP AND HAD NO BRAKES WHAT SO EVER! THE BRAKE LINE GOING TO THE PASSENGER SIDE FRONT CALIPER HAD COMPLETELY RUSTED AWAY UNDER THE MIDDLE OF THE VEHICLE BETWEEN THE PASSENGER SIDE FRONT TIRE AND THE ABS DISTRIBUTION BOX. I WAS ALWAYS TOLD THAT THE BRAKE SYST…
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WAS DRIVING AND EXPERIENCED COMPLETE BRAKE FAILURE, NO WARNING, WENT TO STOP AND HAD NO BRAKES WHAT SO EVER! THE BRAKE LINE GOING TO THE PASSENGER SIDE FRONT CALIPER HAD COMPLETELY RUSTED AWAY UNDER THE MIDDLE OF THE VEHICLE BETWEEN THE PASSENGER SIDE FRONT TIRE AND THE ABS DISTRIBUTION BOX. I WAS ALWAYS TOLD THAT THE BRAKE SYSTEMS WERE DESIGNED WITH A TANDEM MASTER CYLINDER SO THAT IF AN EVENT LIKE THIS HAPPENED YOU WOULD STILL HAVE 2 WHEELS THAT HAD BRAKES. THIS OBVIOUSLY IS NOT THE CASE AS THERE WAS A COMPLETE LOSS OF ALL 4 BRAKES. LUCKILY I WAS ONLY DOING 25 MPH AND THERE WAS NO TRAFFIC WHERE I WAS WHEN THIS HAPPENED, IT TOOK A WAYS TO GET THE VEHICLE STOPPED BY APPLYING THE PARKING BRAKE. I DON'T WANT TO EVEN THINK WHAT WOULD HAPPEN IF I WAS ON THE FREEWAY DOING 70 MPH AND HAD TO STOP IN AN EMERGENCY AND THIS HAPPENED, I WOULD PROBABLY BE DEAD AND POSSIBLY SOMEONE ELSE ALSO. THIS NEEDS TO BE ADDRESSED ASAP. PEOPLES LIVES ARE AT SERIOUS RISK HERE. I CANNOT UNDERSTAND WHY THESE BRAKE LINES WOULD NOT BE MADE OUT OF 318 STAINLESS STEEL, THEY WOULD NEVER CORRODE AND THIS WOULD POSSIBLY SAVE LIVES. I AM TOTALLY CONVINCED THAT PEOPLE HAVE DIED FROM THIS HAPPENING. THIS IS NOTHING NEW WITH FORDS! MY MECHANIC TOLD ME THAT HE SEES FORD VEHICLES ALL THE TIME WITH RUSTED OUT BRAKE LINES AND PEOPLE THAT HAVE EXPERIENCED COMPLETE BRAKE FAILURE DUE TO THIS.
NHTSA ODI #10876646
146,000 miles · Oct 20, 2014
EngineService Brakes
WHILE DRIVING ON THE HIGHWAY THE CAR COMPLETELY SHUT DOWN. ALL LIGHTS ON DASH LIT UP, RADIO WENT OFF. SECONDS LATER THE CAR RESTATED ITSELF AND THE RADIO WENT BACK ON. THIS HAPPENED TWICE ON 10/20/2014 AND ONCE ABOUT TWO WEEKS BEFORE THAT.. NO WARNING LIGHTS COME ON, NO BUMPS THE ROAD WAS SMOOTH, NO RAIN PUDDLES. IT JUST DIES AN…
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WHILE DRIVING ON THE HIGHWAY THE CAR COMPLETELY SHUT DOWN. ALL LIGHTS ON DASH LIT UP, RADIO WENT OFF. SECONDS LATER THE CAR RESTATED ITSELF AND THE RADIO WENT BACK ON. THIS HAPPENED TWICE ON 10/20/2014 AND ONCE ABOUT TWO WEEKS BEFORE THAT.. NO WARNING LIGHTS COME ON, NO BUMPS THE ROAD WAS SMOOTH, NO RAIN PUDDLES. IT JUST DIES AND RESTARTS ITSELF EACH TIME. FOR ABOUT 6 MONTHS NOW THE CAR DIES COMPLETELY WHEN I AM BACKING UP EVERY NOW AND THEN NOT EACH TIME. WE HAD 5 PEOPLE IN THE CAR AND GOT VERY SCARED. I HAVE HAD LOTS OF WORK DONE TO THE CAR AND HAVE RECEIPTS. MECHANIC SAID IT SOUNDS LIKE RAN ELECTRICS PROBLEM THAT COULD BE ONE OF A HUNDRED THINGS. PLEASE HELP WITH A SOLUTION. *TR
NHTSA ODI #10648749
183,797 miles · Jul 21, 2014
Service Brakes
TL* THE CONTACT OWNS A 2005 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING AT AN UNKNOWN SPEED, THE BRAKES WERE ENGAGED BUT FAILED TO STOP THE VEHICLE. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE FAILURE AND CURRENT MILEAGE WAS 183,797.
NHTSA ODI #10614993
67,000 miles · Apr 2, 2014
Service Brakes
I HAVE TALKED TO A FEW OTHER OWNERS OF FORD EXPEDITIONS (LATER MODELS 2004-2008) AND THERE IS A DEFINITE ISSUE WITH RUST AND OTHER COMPONENTS RUSTING OUT. IT SEEMS TO BE A SERIOUS ISSUE WITH RUST ESP WHEN THE BRAKE LINES ARE BASICALLY ALL RUSTED OUT IN THE FRONT OF THE VEHICLE. ALSO THE CROSS MEMBER FRAME UNDERNEATH HAS A LOT MO…
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I HAVE TALKED TO A FEW OTHER OWNERS OF FORD EXPEDITIONS (LATER MODELS 2004-2008) AND THERE IS A DEFINITE ISSUE WITH RUST AND OTHER COMPONENTS RUSTING OUT. IT SEEMS TO BE A SERIOUS ISSUE WITH RUST ESP WHEN THE BRAKE LINES ARE BASICALLY ALL RUSTED OUT IN THE FRONT OF THE VEHICLE. ALSO THE CROSS MEMBER FRAME UNDERNEATH HAS A LOT MORE THAN ACCEPTABLE AMOUNT OF RUST, NEVER SEEN THIS MUCH EVEN WITH A TRUCK I HAVE NOW A 1997 DODGE WITH 190,000 MILES DOESN'T EVEN COME CLOSE TO THE RUST I SEE WITH THE FORD. RUST BUBBLES ON THE REAR LIFT GATE HANDLE AREA AND JUST ABOUT ALL AROUND THE WINDOW AREAS AND THE HOOD. MIND YOU THAT THE TIME WE'VE HAD THE VEHICLE ONLY MAYBE A HANDFUL OF TIMES IT WAS OUT IN SNOW OR EVEN RAINY WEATHER - LOW MILES FOR THE YEAR 67,000/8 YEARS+. THE LINES AND RUST REPAIR WILL COST MONEY $$ TO FIX I BELIEVE THAT FORD KNOWS THERE'S AN ISSUE AND STIFFS THE CONSUMER KNOWING THAT THE MATERIALS RUST OUT CAUSING A VERY UNSAFE VEHICLE TO DRIVE. ANYBODY FOR A CLASS ACTION LAWSUIT HERE? *TR
NHTSA ODI #10576581
Mileage unknown · Mar 31, 2014
Service Brakes
I HAVE A 2005 FORD EXPEDITION WITH ADJUSTABLE HEIGHT OF THE BRAKE PEDDLE. THE ADJUSTMENT DOES NOT WORK AND THE HEIGHT OF THE BRAKE PEDDLE IS AT A HEIGHT THAT WHEN THE BRAKE IS DEPRESSED IT IS ALSO POSSIBLE THAT THE ACCELERATOR IS ALSO DEPRESSED CAUSING UNEXPECTED ACCELERATION. I HAVE CONTACTED MY LOCAL DEALER AND WWW.FORD.COM AB…
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I HAVE A 2005 FORD EXPEDITION WITH ADJUSTABLE HEIGHT OF THE BRAKE PEDDLE. THE ADJUSTMENT DOES NOT WORK AND THE HEIGHT OF THE BRAKE PEDDLE IS AT A HEIGHT THAT WHEN THE BRAKE IS DEPRESSED IT IS ALSO POSSIBLE THAT THE ACCELERATOR IS ALSO DEPRESSED CAUSING UNEXPECTED ACCELERATION. I HAVE CONTACTED MY LOCAL DEALER AND WWW.FORD.COM ABOUT THIS SAFETY ISSUE AND BOTH HAVE TOLD ME THAT THERE IS NO RECALL AND THAT THEY WILL NOT FIX OR ASSIST ME ON THIS. I BELIEVE THAT THE SUDDEN ACCELERATION IS A SERIOUS SAFETY CONCERN AND SHOULD BE ADDRESSED BY NHTSA. *TR
NHTSA ODI #10575920
152,000 miles · Dec 9, 2013
Electrical SystemEngineService Brakes
I WAS DRIVING WITH 4 KIDS IN THE CAR, WHEN ALL THE SUDDEN MY CAR TURNED OFF, ALL THE LIGHTS CAME ON THE DASH. LUCKILY I WAS ABLE TO MOVE OVER TO A PARKING LOT. I TURNED THE CAR OFF, TURNED BACK ON, NOTHING. TRIED AGAIN AND IT WORKED. I WAS ABLE TO DRIVE 50 MILES HOME AND AS I WAS TURNING IN MY DRIVEWAY IT HAPPENED AGAIN. *TR
NHTSA ODI #10555394
88,000 miles · Mar 2, 2013
Electrical SystemEngineService Brakes
WHILE DRIVING AT 40 MPH ENGINE STOPPED WORKING MAKING BRAKES AND STEERING FAIL. LIMPED OFF BUSY ROAD LUCKILY! ENGINE LIGHT SHOWED ELECTRONIC THROTTLE FAILURE. NOW CHECK ENGINE LIGHT IS ON. GOING TO DEALERS FOR REPAIR TODAY-SINCE THIS IS AN OBVIOUS PROBLEM FOR FORD WHY HAVEN'T THEY ADDRESSED IT! COULD BE DEADLY IF FAILS IN HEA…
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WHILE DRIVING AT 40 MPH ENGINE STOPPED WORKING MAKING BRAKES AND STEERING FAIL. LIMPED OFF BUSY ROAD LUCKILY! ENGINE LIGHT SHOWED ELECTRONIC THROTTLE FAILURE. NOW CHECK ENGINE LIGHT IS ON. GOING TO DEALERS FOR REPAIR TODAY-SINCE THIS IS AN OBVIOUS PROBLEM FOR FORD WHY HAVEN'T THEY ADDRESSED IT! COULD BE DEADLY IF FAILS IN HEAVY TRAFFIC CONDITIONS. *TR
NHTSA ODI #10501011
59,500 miles · Aug 21, 2012
Service Brakes
DRIVING THE VEHICLE AND I ATTEMPTED TO STOP AND THE BRAKE PEDAL WENT TO THE FLOOR, EVEN AFTER PUMPING THE BRAKES. SOON AFTERWARD THE LOW FLUID LIGHT WENT ON. I HAD THE VEHICLE TAKEN TO MY LICENSED MECHANIC WHO DIAGNOSED THE PROBLEM AS A RUSTED THROUGH BRAKE LINE. SEVERAL OTHER LOCATIONS WERE HEAVILY RUSTED AND LEAKING AS WEL…
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DRIVING THE VEHICLE AND I ATTEMPTED TO STOP AND THE BRAKE PEDAL WENT TO THE FLOOR, EVEN AFTER PUMPING THE BRAKES. SOON AFTERWARD THE LOW FLUID LIGHT WENT ON. I HAD THE VEHICLE TAKEN TO MY LICENSED MECHANIC WHO DIAGNOSED THE PROBLEM AS A RUSTED THROUGH BRAKE LINE. SEVERAL OTHER LOCATIONS WERE HEAVILY RUSTED AND LEAKING AS WELL. I WAS VERY FORTUNATE NOT TO HIT ANYONE, ESPECIALLY SINCE I HAD 5 CHILDREN IN THE VEHICLE WITH ME AT THE TIME OF THE INCIDENT. I HAVE BEEN THE ONLY THE OWNER AND ORDERED THE VEHICLE NEW FROM FORD. THIS VEHICLE IS LIGHTLY USED AND NOT GARAGED. *TR
NHTSA ODI #10471808
Official recalls
0
No 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
1
PE08070 · 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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