NHTSA owner reports · September 18, 2026 snapshot.
What owners actually said
315 reports67,000 miles · Feb 2, 2012
Electrical SystemFuel System, Gasoline
VEHICLE HAS BEEN STALLING FOR ALMOST A YEAR. VEHICLE SHUT OFF ON BUSY HIGHWAY AND TOWED TO NEARBY REPAIR SHOP. MECHANIC FOUND FUEL PUMP CONTROL MODULE COMPLETELY CORRODED FROM BEHIND AND CIRCUIT BOARD EXPOSED TO MOISTURE. THE FPCM FRIED AND SHORTED OUT ONE LEG OF THE FUEL PUMP. BOTH PIECES HAD TO BE REPLACED. NEW FPCM INSTALLE…
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VEHICLE HAS BEEN STALLING FOR ALMOST A YEAR. VEHICLE SHUT OFF ON BUSY HIGHWAY AND TOWED TO NEARBY REPAIR SHOP. MECHANIC FOUND FUEL PUMP CONTROL MODULE COMPLETELY CORRODED FROM BEHIND AND CIRCUIT BOARD EXPOSED TO MOISTURE. THE FPCM FRIED AND SHORTED OUT ONE LEG OF THE FUEL PUMP. BOTH PIECES HAD TO BE REPLACED. NEW FPCM INSTALLED WAS OBVIOUSLY REDESIGNED SO MODULE WOULD NOT SUFFER THIS FLAW AGAIN. I AM FINDING AN ALARMING AMOUNT OF COMPLAINTS ON THE INTERNET OF FORD EXPEDITION OWNER EXPERIENCING THE EXACT SAME PROBLEMS UNDER MORE DANGEROUS CONDITIONS. *KB
NHTSA ODI #10446313
Mileage unknown · Jan 29, 2012
Fuel System, Gasoline
VEHICLE STOPED RUNNING ON FLAT LEVEL READ AT 65 MILES PER HOUR.VEHICLE WOULD NOT RESTART. VEHICLE HAD BEEN STALLING PRIOR. MECHANIC CANT PINPOINT PROBLEM BUT FEELS FUEL PUMP, FUEL PUMP MODULE, FUES BOX MALFUNCTION ARE THE CAUSE. TO MANY STORIES OF THIS PROBLEM SURFACING. MY FAMILY IN DANGER WITH VEHICLE STOPPED ON MAJOR HIGHWAY,…
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VEHICLE STOPED RUNNING ON FLAT LEVEL READ AT 65 MILES PER HOUR.VEHICLE WOULD NOT RESTART. VEHICLE HAD BEEN STALLING PRIOR. MECHANIC CANT PINPOINT PROBLEM BUT FEELS FUEL PUMP, FUEL PUMP MODULE, FUES BOX MALFUNCTION ARE THE CAUSE. TO MANY STORIES OF THIS PROBLEM SURFACING. MY FAMILY IN DANGER WITH VEHICLE STOPPED ON MAJOR HIGHWAY, CAUSED BY A WELL KNOWN PROBLEM FORD IS AWARE OF. *TT
NHTSA ODI #10445741
76,000 miles · Jan 22, 2012
Engine And Engine CoolingVehicle Speed Control
I WAS DRIVING MY CAR WHEN ALL OF A SUDDEN THE ACCELERATOR IS NOT RESPONDING AND SO I NEED TO COAST THE CAR TO THE CURVE. I CALLED THE DEALER AND SO MY CAR WAS STILL UNDER MY EXTENDED WARRANTY AND SO I TOOK THE CAR IN AND I WAS TOLD THAT THEY REPLACED THE PART THIS WAS IN MARCH 2009, IT IS NOW JANUARY 21, 2012 AND I HAD THE SAME…
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I WAS DRIVING MY CAR WHEN ALL OF A SUDDEN THE ACCELERATOR IS NOT RESPONDING AND SO I NEED TO COAST THE CAR TO THE CURVE. I CALLED THE DEALER AND SO MY CAR WAS STILL UNDER MY EXTENDED WARRANTY AND SO I TOOK THE CAR IN AND I WAS TOLD THAT THEY REPLACED THE PART THIS WAS IN MARCH 2009, IT IS NOW JANUARY 21, 2012 AND I HAD THE SAME PROBLEM. THE MESSAGE BOARD READS, CHECK ELECTRONIC THROTTLE SYSTEM. *TR
NHTSA ODI #10444763
50,000 miles · Jan 11, 2012
Fuel System, Gasoline
2005 FORD EXPEDITION HAS EXPERIENCED APPROXIMATELY 5 EPISODES WHERE IT HAS STALLED WITH NO NOTICE OR PRIOR INDICATION OF A PROBLEM. THE PROBLEM STARTED AROUND 50K MILES AND HAPPENED MOST RECENTLY AS ABOUT 120K MILES. ON AT LEAST 2 OCCASIONS THE CENTER DASH INDICATED ENGINE FAILSAFE MODE. EACH TIME, THE TRUCK COULD BE IMMEDIATE…
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2005 FORD EXPEDITION HAS EXPERIENCED APPROXIMATELY 5 EPISODES WHERE IT HAS STALLED WITH NO NOTICE OR PRIOR INDICATION OF A PROBLEM. THE PROBLEM STARTED AROUND 50K MILES AND HAPPENED MOST RECENTLY AS ABOUT 120K MILES. ON AT LEAST 2 OCCASIONS THE CENTER DASH INDICATED ENGINE FAILSAFE MODE. EACH TIME, THE TRUCK COULD BE IMMEDIATELY RESTARTED AND WOULD OPERATE NORMALLY. THE ONLY COMMON CIRCUMSTANCE IS THAT THE TRUCK WAS COASTING TO A LOWER SPEED AT THE TIME OF THE FAILURE. NO CODES ARE RECORDED, SO NO TROUBLESHOOTING CAN BE PERFORMED. REPLACED THE THROTTLE POSITION SENSOR, BUT FAILURE HAS OCCURRED TWICE SINCE. THE NEXT STEP IS TO REPLACE THE THROTTLE BODY ASSEMBLY. *TR
NHTSA ODI #10443463
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
92,000 miles · Dec 14, 2011
Vehicle Speed Control
AT 45 MPH I LOST THROTTLE CONTROL AND WARNING LIGHT CAME ON INDICATING "ELECTRONIC THROTTLE CONTROL". I DRIFTED TO THE SIDE OF THE ROAD, PUT IN PARK AND TURNED OFF ENGINE. I RESTARTED AND EVERYTHING WAS FINE AND WARNING LIGHT WAS GONE. HAS BEEN FINE FOR THE PAST COUPLE OF WEEKS. READING EVERYBODY'S CONCERNS ON THIS ISSUE MAKES M…
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AT 45 MPH I LOST THROTTLE CONTROL AND WARNING LIGHT CAME ON INDICATING "ELECTRONIC THROTTLE CONTROL". I DRIFTED TO THE SIDE OF THE ROAD, PUT IN PARK AND TURNED OFF ENGINE. I RESTARTED AND EVERYTHING WAS FINE AND WARNING LIGHT WAS GONE. HAS BEEN FINE FOR THE PAST COUPLE OF WEEKS. READING EVERYBODY'S CONCERNS ON THIS ISSUE MAKES ME WONDER IF THERE REALLY IS A FIX FOR THIS. I CERTAINLY DON'T TRUST THE DEALERS......WHAT'S UP FORD??? *TR
NHTSA ODI #10439987
134,500 miles · Oct 31, 2011
Electrical SystemVehicle Speed Control
TRAVELING ALONG CONGESTED CITY STREET DURING MORNING RUSH AND VEHICLE LOOSES ALL POWER. INSTRUMENT CLUSTER LIGHTS ARE ALL ON. MESSAGE SAY "CHECK ELECTRONIC THROTTLE" I WAS ABLE TO TURN THE VEHICLE OFF AND BACK ON TWICE BEFORE THE ERROR CLEARED. I HAVE AN APPOINTMENT AT THE DEALERSHIP IN THE MORNING. BUT THESE OTHER REPORTS DON'…
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TRAVELING ALONG CONGESTED CITY STREET DURING MORNING RUSH AND VEHICLE LOOSES ALL POWER. INSTRUMENT CLUSTER LIGHTS ARE ALL ON. MESSAGE SAY "CHECK ELECTRONIC THROTTLE" I WAS ABLE TO TURN THE VEHICLE OFF AND BACK ON TWICE BEFORE THE ERROR CLEARED. I HAVE AN APPOINTMENT AT THE DEALERSHIP IN THE MORNING. BUT THESE OTHER REPORTS DON'T GIVE ME MUCH HOPE. AND I JUST PAID OFF THE NOTE LAST WEEK. *TR
NHTSA ODI #10433681
Mileage unknown · Sep 23, 2011
Structure
MY 2005 FORD EXPEDITION WITH JUST 62,000 MILES ON IT HAS CHIPPING AND BUBBLING PAINT ON THE REAR LIFT GATE AND THE HOOD. TALKED TO MY LOCAL FORD DEALER AND THEY SAID THAT THEIR WAS AN ISSUE WITH THE ALUMINUM PRIOR TO PAINTING THESE TWO PARTS AT THE FACTORY. FORD IS NOT STANDING BEHIND THIS DEFECT. *TR
NHTSA ODI #10426947
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
101,000 miles · Sep 18, 2011
Electrical SystemEngine And Engine Cooling
2005 EXPEDITION RANDOMLY STALLS AT VARIOUS SPEEDS USUALLY AROUND 45 - 50 MILES PER HOUR. YOU HAVE TO TRY TO GET TO THE SIDE OF THE ROAD, STOP AND GIVE THE CAR A COUPLE OF MINUTES AND CRANK IT AGAIN. I HAVE TAKEN TO FORD DEALERSHIP AND I NEED A THROTTLE POSITION SENSOR. IT WILL BE $700 TO FIX. THE PERSON THAT OWNED THE VEHICL…
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2005 EXPEDITION RANDOMLY STALLS AT VARIOUS SPEEDS USUALLY AROUND 45 - 50 MILES PER HOUR. YOU HAVE TO TRY TO GET TO THE SIDE OF THE ROAD, STOP AND GIVE THE CAR A COUPLE OF MINUTES AND CRANK IT AGAIN. I HAVE TAKEN TO FORD DEALERSHIP AND I NEED A THROTTLE POSITION SENSOR. IT WILL BE $700 TO FIX. THE PERSON THAT OWNED THE VEHICLE BEFORE ME HAD ALREADY REPLACED THIS SAME PART. MY CONCERN IS I SPEND THE $700 AND STILL HAVE THE SAME PROBLEM. THIS IS A SERIOUS SAFETY ISSUE, I STAY IN CONSTANT FEAR THAT IT IS GOING TO STALL AT ANY MINUTE. I CAN'T BELIEVE FORD HAS NOT RECALLED THIS. THIS IS MY SECOND FORD BUT WILL BE MY LAST. *TT
NHTSA ODI #10425983
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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