NHTSA owner reports · September 18, 2026 snapshot.
What owners actually said
315 reports102,000 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
97,000 miles · May 29, 2012
Engine
WHILE DRIVING ON ROAD IN TRAFFIC, THE ENGINE WAS BUCKING AND TURNING OFF, CAUSING TRAFFIC TO SWERVE AROUND ME UNTIL I COULD GET OFF THE ROAD. WARNING LIGHT SAID ELECTRONIC THROTTLE CONTROL. TOOK TO DEALER FOR INSPECTION. *TR
NHTSA ODI #10459882
61,000 miles · May 21, 2012
Air BagsInjury
IN TRYING TO AVOID DEBRIS THE SUV FLIP AND SLIDING DOWN THE HWY I HIT A TRACTOR TRAILER REAR TIRE,THE AIR BAGS DID NOT DEPLOY. *TT
NHTSA ODI #10459195
120,000 miles · May 3, 2012
Electrical System
TL* THE CONTACT OWNS A 2005 FORD EXPEDITION. WHILE DRIVING APPROXIMATELY 30 MPH, THE VEHICLE SUDDENLY STALLED. THE ENGINE WARNING LIGHT ILLUMINATED ON THE INSTRUMENT PANEL AND A WARNING NOTIFICATION APPEARED, INDICATING THERE WAS A CHARGING SYSTEM FAILURE. THE VEHICLE WAS TOWED TO THE DEALER FOR DIAGNOSTIC TESTING AND THE TECHN…
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TL* THE CONTACT OWNS A 2005 FORD EXPEDITION. WHILE DRIVING APPROXIMATELY 30 MPH, THE VEHICLE SUDDENLY STALLED. THE ENGINE WARNING LIGHT ILLUMINATED ON THE INSTRUMENT PANEL AND A WARNING NOTIFICATION APPEARED, INDICATING THERE WAS A CHARGING SYSTEM FAILURE. THE VEHICLE WAS TOWED TO THE DEALER FOR DIAGNOSTIC TESTING AND THE TECHNICIAN STATED THE COMPUTER HAD TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE APPROXIMATE FAILURE MILEAGE WAS 120,000.
NHTSA ODI #10457376
45,000 miles · Apr 29, 2012
Engine And Engine CoolingFuel System, Gasoline
ENGINE STOPS RUNNING AT DIFFERENT SPEEDS. SYSTEM DISPLAYS A CHECK ELECTRONIC THROTTLE CONTROL ERROR. THIS IS VERY DANGEROUS. *TR
NHTSA ODI #10456808
80,000 miles · Mar 15, 2012
Engine And Engine Cooling
TL* THE CONTACT OWNS A 2005 FORD EXPEDITION. WHILE DRIVING APPROXIMATELY 55 MPH, THE ENGINE STALLED WITH THE ILLUMINATION OF THE WARNING INDICATOR. THE ENGINE RESTARTED AFTER WAITING A FEW MOMENTS AND RESUMED AS NORMAL. THE FAILURE RECURRED THREE TIMES WHILE DRIVING AT VARIOUS SPEEDS. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECH…
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TL* THE CONTACT OWNS A 2005 FORD EXPEDITION. WHILE DRIVING APPROXIMATELY 55 MPH, THE ENGINE STALLED WITH THE ILLUMINATION OF THE WARNING INDICATOR. THE ENGINE RESTARTED AFTER WAITING A FEW MOMENTS AND RESUMED AS NORMAL. THE FAILURE RECURRED THREE TIMES WHILE DRIVING AT VARIOUS SPEEDS. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC FOR DIAGNOSIS BUT THEY WERE UNABLE TO DETECT A FAILURE CODE. THE MANUFACTURER WAS NOTIFIED OF THE PROBLEM. THE APPROXIMATE FAILURE MILEAGE WAS 80,000.
NHTSA ODI #10451784
88,000 miles · Mar 13, 2012
Electrical SystemFire
I WAS DRIVING ON FOUR LANE HIGHWAY IN RIGHT LANE AT 40MPH. I NOTICED THE CAR STARTING TO SLOW DOWN AND WHEN I PRESSED THE GAS PEDAL IT DID NOT REACT AND THE CAR CONTINUED TO SLOW DOWN. I LOOKED AT MY GAUGES ON THE DASH AND THERE WERE NO WARNING LIGHTS AND ALL GAUGES READ NORMALLY. I THOUGHT I COULD SMELL SMOKE, AND THE CAR CO…
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I WAS DRIVING ON FOUR LANE HIGHWAY IN RIGHT LANE AT 40MPH. I NOTICED THE CAR STARTING TO SLOW DOWN AND WHEN I PRESSED THE GAS PEDAL IT DID NOT REACT AND THE CAR CONTINUED TO SLOW DOWN. I LOOKED AT MY GAUGES ON THE DASH AND THERE WERE NO WARNING LIGHTS AND ALL GAUGES READ NORMALLY. I THOUGHT I COULD SMELL SMOKE, AND THE CAR CONTINUED TO SLOW DOWN, AND I KNEW I NEEDED TO GET OFF THE ROAD AS TRAFFIC WAS HEAVY. AS I PULLED OFF THE ROAD INTO THE PARKING LOT FOR THE STRIP MALL, THE CAR STALLED, LIGHTS CAME ON THE DASH TO INDICATE THE CAR STALLED AND I WAS ABLE TO STOP THE CAR, PUT IT IN PARK AND TURN THE CAR OFF. I COULD SMELL SMOKE AND I COULD SEE SMOKE GOING OUT THE CAR WINDOWS FROM INSIDE THE CAR AS I HAD THE WINDOWS OPEN A COUPLE OF INCHES. THERE WAS NO SMOKE COMING FROM UNDER THE HOOD. I DEBATED WHETHER TO CALL AAA OR 911. AS THE SMOKE INCREASED I CALLED 911. I THEN WENT TO THE CAR TO GET MY PURSE. WHEN I OPENED THE PASSENGER FRONT DOOR THE CAR WAS FILLED WITH SMOKE AND I THOUGHT I COULD SEE FIRE IN THE MIDDLE ROW OF SEAT ON THE FLOOR. I OPENED THE BACK DOOR ON THE PASSENGER SIDE AND SAW FLAMES SHOOTING UP FROM THE FLOOR 6 INCHES HIGH IN THE CENTER OF THE FLOOR. I TRIED TO PUT OUT THE FIRE WITH A SNOW SCRAPER WITH THE BRUSH END, BUT I WAS NOT SUCCESSFUL. I ASKED THE DRY CLEANING LADY IF SHE HAD A FIRE EXTINGUISHER. IT TOOK 30 SECONDS TO GET THE EXTINGUISHER AND ON MY WAY BACK TO THE CAR, I COULD SEE FLAMES UNDER THE CAR AND WHEN I OPENED THE BACK PASSENGER DOOR THE FIRE HAD SPREAD TO THE BACK SEAT. I WAS FEARFUL FOR HOW FAST THE FIRE SPREAD AND THE SMOKE PREVENTED ME FROM REACHING THE FIRE WITH THE EXTINGUISHER. THE FIRE DEPARTMENT THEN ARRIVED AND IT TOOK THEM 15-20 MINUTES TO PUT OUT THE FIRE AS THE FLAMES WERE SHOOTING AT LEAST 20 FEET INTO THE AIR. THE CAR WAS COMPLETELY ENGULFED IN FLAMES. I HAVE PICTURES I TOOK WITH MY PHONE. *TR
NHTSA ODI #10451540
77,850 miles · Feb 6, 2012
Electrical SystemVehicle Speed Control
I WAS DRIVING THE VEHICLE AND IT IMMEDIATELY LOST ACCELERATION. AN ALARM ON DASH IDENTIFIED THE PROBLEMS AS ELECTRONIC THROTTLE CONTROL FAILURE. THIS WAS VERY DANGEROUS AND I WAS LUCKY NO ONE WAS FOLLOWING ME CLOSE. MY WIFE IS NOW SCARED TO DRIVE THE VEHICLE AND I DON'T KNOW WHAT TO DO. THERE ARE MANY COMPLAINTS ON THE WEB ABOUT…
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I WAS DRIVING THE VEHICLE AND IT IMMEDIATELY LOST ACCELERATION. AN ALARM ON DASH IDENTIFIED THE PROBLEMS AS ELECTRONIC THROTTLE CONTROL FAILURE. THIS WAS VERY DANGEROUS AND I WAS LUCKY NO ONE WAS FOLLOWING ME CLOSE. MY WIFE IS NOW SCARED TO DRIVE THE VEHICLE AND I DON'T KNOW WHAT TO DO. THERE ARE MANY COMPLAINTS ON THE WEB ABOUT THIS ISSUE WHICH I WOULD HAVE THOUGHT A RECALL WOULD BE INITIATED BY FORD. I SEARCHED AND FOUND OUT THAT THERE WAS NO RECALL ON THIS ISSUE. I CALLED FORD MOTOR COMPANY AND THEY INFORMED ME THAT I WAS THE FIRST ONE TO COMPLAIN ABOUT THIS ISSUE. I FIND THAT VERY HARD TO BELIEVE WITH EVERYTHING I HAVE READ ON THE WEBSITE. ANYONE ONE WHO READS THIS THAT HAS HAD THE PROBLEM SHOULD CALL FORD MOTOR COMPANY AND COMPLAIN. JUST GO TO FORD.COM AND CLICK ON SUPPORT TO GET THE PHONE NUMBER. *TR
NHTSA ODI #10446871
101,000 miles · Feb 6, 2012
Engine And Engine Cooling
TL* THE CONTACT OWNS A 2005 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING 35 MPH, THE VEHICLE WOULD ENGAGE INTO SAFE MODE ERRONEOUSLY AND STALL. THE CONTACT HAD TO SHUT OFF AND RESTART THE VEHICLE IN ORDER TO HAVE THE VEHICLE FUNCTION PROPERLY. THE CONTACT DID NOT TAKE THE VEHICLE TO THE DEALER FOR A DIAGNOSTIC TEST …
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TL* THE CONTACT OWNS A 2005 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING 35 MPH, THE VEHICLE WOULD ENGAGE INTO SAFE MODE ERRONEOUSLY AND STALL. THE CONTACT HAD TO SHUT OFF AND RESTART THE VEHICLE IN ORDER TO HAVE THE VEHICLE FUNCTION PROPERLY. THE CONTACT DID NOT TAKE THE VEHICLE TO THE DEALER FOR A DIAGNOSTIC TEST OR REPAIRS. THE CONTACT CALLED THE MANUFACTURER AND FILED A COMPLAINT. THE FAILURE MILEAGE WAS 101,000.
NHTSA ODI #10446807
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
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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