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2005 Ford Expedition

Owner reports · Recalls · Investigations

More warning signs than most Expedition years

Owner complaints for the 2005 Ford Expedition are substantially higher than the model-year median of 155.

About this comparison →

When problems were reported

Mileage at the reported incident

289 reports with mileage · 26 unknown

NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.

What to inspect

Issues worth paying extra attention to based on owner reports.

  • Electrical System. Review the 76 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Vehicle Speed Control. Review the 66 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Engine. Review the 57 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

20 crash reports6 fire reports10 injury reports

What owners actually said

315 reports
90,000 miles · Aug 15, 2011
Power TrainVehicle Speed Control

2005 FORD EXPEDITION EDDIE BAUER, 90,000 MILES. (VEHICLE MANUFACTURED IN 2004.) WHILE BEING DRIVEN AT HIGHWAY SPEED THROTTLE STUCK IN FULLY DEPRESSED POSITION AFTER BEING ENGAGED FOR A ROUTINE PASS OF ANOTHER VEHICLE. VEHICLE WAS NOTED TO ACCELERATE. ACCELERATOR PEDAL COULD NOT BE RETURNED TO NON-DEPRESSED STATE WHEN FORCE …

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2005 FORD EXPEDITION EDDIE BAUER, 90,000 MILES. (VEHICLE MANUFACTURED IN 2004.) WHILE BEING DRIVEN AT HIGHWAY SPEED THROTTLE STUCK IN FULLY DEPRESSED POSITION AFTER BEING ENGAGED FOR A ROUTINE PASS OF ANOTHER VEHICLE. VEHICLE WAS NOTED TO ACCELERATE. ACCELERATOR PEDAL COULD NOT BE RETURNED TO NON-DEPRESSED STATE WHEN FORCE APPLIED. BRAKES APPLIED FORCEFULLY, VEHICLE WAS UNABLE TO BE SLOWED OR BROUGHT TO A STOP. STRONG SMELL OF "BURNING" BRAKE PADS WAS NOTED. ATTEMPTED TO SHIFT VEHICLE INTO AUTOMATIC TRANSMISSION POSITION OF NEUTRAL. NO CHANGE IN ENGINE SPEED NOTED. TRANSMISSION THEN SHIFTED INTO REVERSE. VEHICLE WHEELS LOCKED UP AND VEHICLE SKIDDED APPROXIMATELY 100 - 150 FEET BEFORE COMING TO A STOP. ANTILOCK SYSTEM AND OTHER SYSTEMS DID NOT ACTIVATE. AFTER COMING TO A STOP, THROTTLE PEDAL WAS INSPECTED. NO INTERIOR INTERFERENCE FROM FLOOR MATS OR OTHER MATERIALS NOTED. OPERATOR IS 100% CERTAIN AS A RESULT OF "REAL-TIME" VISUAL CONFIRMATION, THAT ACCELERATOR AND BRAKE PEDALS WERE NOT MISTAKENLY ENGAGED OR DUALLY ENGAGED. CRUISE CONTROL WAS NOT ENGAGED. VEHICLE HAS BEEN SERVICED AND MAINTAINED REGULARLY AND WITH PRECISION AND DETAIL. VEHICLE WAS INSPECTED BY AN INDEPENDENT MECHANIC IMMEDIATELY POST THE INCIDENT. THROTTLE BODY FOUND TO BE FOULED AND DIRTY. INDEPENDENT MECHANIC IS REASONABLY CERTAIN THAT DIRTY THROTTLE BODY IS MOST LIKELY CAUSE OF THIS EVENT. INDEPENDENT MECHANIC HAS PERSONAL KNOWLEDGE AND EXPERIENCE OF SIMILAR THROTTLE BODY FAILURES PRODUCING SIMILAR EVENTS AS HAS BEEN DESCRIBED ABOVE. THIS VEHICLE HAS HAD OTHER PREMATURE FAILURES, INCLUDING (1) NEED FOR TRANSMISSION AND TRANSFER CASE TO BE REBUILT AT 28,000 MILES; (2) FAILURE OF POWER DRIVER'S SEAT TO MOVE ON ITS TRACK AT 25,000 MILES; (3) PREMATURE CAM PHASER FAILURE AND REBUILD AT APPROXIMATELY 35,000 MILES. *TR

NHTSA ODI #10419439

93,000 miles · Jun 20, 2011
Electrical System

OUR VEHICLE IS A 2005 FORD EXPEDITION LIMITED. ON TWO OCCASIONS THIS VEHICLE HAS UNEXPEDTEDLY LOST ALL POWER WITH THE MESSAGE "CHECK ELECTRONIC THROTTLE" APPEARING. ON ONE OCCASSION WE WERE MAKING A LEFT TURN ON A BUSY ROAD. WHEN THE VEHICLE LOST POWER WE WERE STUCK IN THE MIDDLE OF THE ROAD WITH ONCOMING TRAFFIC HAVING TO ST…

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OUR VEHICLE IS A 2005 FORD EXPEDITION LIMITED. ON TWO OCCASIONS THIS VEHICLE HAS UNEXPEDTEDLY LOST ALL POWER WITH THE MESSAGE "CHECK ELECTRONIC THROTTLE" APPEARING. ON ONE OCCASSION WE WERE MAKING A LEFT TURN ON A BUSY ROAD. WHEN THE VEHICLE LOST POWER WE WERE STUCK IN THE MIDDLE OF THE ROAD WITH ONCOMING TRAFFIC HAVING TO STOP SUDDENLY TO KEEP FROM HITTING US BROADSIDE. TURNING OFF THE IGNITION AND RESTARTING THE CAR MADE THE PROBLEM GO AWAY. LAST WEEK MY WIFE AND SON WERE IN THE VEHICLE COMING TO A STOP AT AN INTERSECTION. WHEN APPLYING THE BRAKE THE VEHICLE SUDDENLY ACCELERATED. MY WIFE HAD TO BREAK HARD AND NARROWLY MISSED HITTING THE CAR IN FRONT OF HER. THE VEHICLE WAS BROUGHT TO THE DEALERSHIP WHERE I WAS INFORMED THAT THEY WILL NEED TO REPLACE THE THROTTLE BODY. AFTER RESAEARCHING THIS ISSUE ON THE INTERNET IT APPEARS THAT BOTH THESE PROBLEMS ARE COMMON WITH THE 2005 EXPEDITION. IF THIS VEHICLE HAS NOT SERIOUSLY INJURED OR KILLED SOMEONE YET IT IS AMAZING AND JUST A MATTER OF TIME BEFORE IT HAPPENS. I DO NOT UNDERSTAND WHY THIS PROBLEM IS BEING IGNORED BY FORD! *TT

NHTSA ODI #10407527

63,000 miles · Jun 16, 2011
Power Train

TL* THE CONTACT OWNS A 2005 FORD EXPEDITION. THE CONTACT STATED THAT THE VEHICLE STALLED AND RESTARTED INDEPENDENTLY WITHIN MINUTES. THE OVERDRIVE WARNING INDICATOR WAS ILLUMINATED AND THE ENGINE BEGAN TO EXHIBIT ABNORMALLY LOUD NOISES. IN ADDITION, THE VEHICLE WOULD NOT SHIFT GEARS. THE VEHICLE WAS TOWED TO THE DEALER WHO DIAG…

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TL* THE CONTACT OWNS A 2005 FORD EXPEDITION. THE CONTACT STATED THAT THE VEHICLE STALLED AND RESTARTED INDEPENDENTLY WITHIN MINUTES. THE OVERDRIVE WARNING INDICATOR WAS ILLUMINATED AND THE ENGINE BEGAN TO EXHIBIT ABNORMALLY LOUD NOISES. IN ADDITION, THE VEHICLE WOULD NOT SHIFT GEARS. THE VEHICLE WAS TOWED TO THE DEALER WHO DIAGNOSED THAT THE TRANSMISSION WAS DEFECTIVE AND NEEDED TO BE REPLACED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE WHO DID NOT OFFER ANY ASSISTANCE SINCE THE VEHICLE WAS OUT OF WARRANTY. THE VEHICLE WAS NOT REPAIRED. THE FAILURE AND CURRENT MILEAGE WAS 63,000.

NHTSA ODI #10407163

87,000 miles · Jun 14, 2011
Air Bags

MY WIFE AND 3 CHILDREN WERE DRIVING MY 2005 FORD EXPEDITION DOWN HWY 29 IN LAKE COUNTY, CA. WHEN THE 2 FRONT AIRBAGS SUDDENLY DEPLOYED. THERE WAS NO ACCIDENT OR IMPACT. LUCKILY MY WIFE WAS ABLE TO RETAIN CONTROL OF THE VEHICLE BUT HAS INJURIES HER CHEST AND NECK. THE CODES FROM THE VEHICLE DO NOT INDICATE ANY ERROR OR MALFUNCTI…

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MY WIFE AND 3 CHILDREN WERE DRIVING MY 2005 FORD EXPEDITION DOWN HWY 29 IN LAKE COUNTY, CA. WHEN THE 2 FRONT AIRBAGS SUDDENLY DEPLOYED. THERE WAS NO ACCIDENT OR IMPACT. LUCKILY MY WIFE WAS ABLE TO RETAIN CONTROL OF THE VEHICLE BUT HAS INJURIES HER CHEST AND NECK. THE CODES FROM THE VEHICLE DO NOT INDICATE ANY ERROR OR MALFUNCTION. IT WOULD MAKE SENSE THAT THIS INCIDENT IS RELATED TO THE F-150 RECALL ISSUE. *TR

NHTSA ODI #10406237

100,000 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

114,000 miles · May 18, 2011
Engine And Engine Cooling

WHILE TRAVELING 60-65 MPH, IN THE FAST LINE OF A FOUR LANE INTERSTATE, MY 2005 FORD EXPEDITION SUFFERED ENGINE FAILURE. I WAS ABLE TO SAFELY GET MY CAR OFF THE INTERSTATE WITHOUT HARMING MYSELF OR MY CHILDREN. THE MECHANIC INFORMED US A ROCKER PIN HAD BROKEN AND CAUSED DAMAGE TO A PISTON RESULTING IN THE NEED FOR A NEW ENGINE…

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WHILE TRAVELING 60-65 MPH, IN THE FAST LINE OF A FOUR LANE INTERSTATE, MY 2005 FORD EXPEDITION SUFFERED ENGINE FAILURE. I WAS ABLE TO SAFELY GET MY CAR OFF THE INTERSTATE WITHOUT HARMING MYSELF OR MY CHILDREN. THE MECHANIC INFORMED US A ROCKER PIN HAD BROKEN AND CAUSED DAMAGE TO A PISTON RESULTING IN THE NEED FOR A NEW ENGINE. I AM REPORTING THE INCIDENT TO YOU BECAUSE WHEN WE PICKED UP OUR CAR AT THE SERVICE DEPARTMENT, HAVING HAD THE ENGINE REPLACED, WE WERE TOLD THAT THERE WERE TWO OTHER FORDS (1EXPEDITION AND 1F150) THAT CAME IN AFTER OURS WITH THE SAME ISSUE. *TR

NHTSA ODI #10401528

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

103,000 miles · May 4, 2011
Fuel System, Gasoline

TL*THE CONTACT OWNS A 2005 FORD EXPEDITION. THE CONTACT STATED THE FUEL PUMP DRIVER MODULE FAILED. THE CONTACT STATED WHILE DRIVING 65 MPH THE VEHICLE STALLED WITHOUT WARNING. THE FUEL PUMP DRIVER MODULE WAS LOCATED IN THE REAR OF THE VEHICLE NEAR THE FUEL TANK. THE FAILURE DESTROYED THE FUEL PUMP AND BLEW THE 15 AMP FUSE THAT A…

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TL*THE CONTACT OWNS A 2005 FORD EXPEDITION. THE CONTACT STATED THE FUEL PUMP DRIVER MODULE FAILED. THE CONTACT STATED WHILE DRIVING 65 MPH THE VEHICLE STALLED WITHOUT WARNING. THE FUEL PUMP DRIVER MODULE WAS LOCATED IN THE REAR OF THE VEHICLE NEAR THE FUEL TANK. THE FAILURE DESTROYED THE FUEL PUMP AND BLEW THE 15 AMP FUSE THAT ALLOWS THE FUEL PUMP TO FUNCTION. THE DEALER INFORMED THE CONTACT THAT THE PART WAS CURRENTLY ON BACK ORDER. THE FAILURE AND CURRENT MILEAGES WERE 103,000.

NHTSA ODI #10398906

51,000 miles · May 2, 2011
Engine And Engine Cooling

TL*THE CONTACT OWNS A 2005 FORD EXPEDITION. THE CONTACT STATED WHILE DRIVING 70 MPH THE VEHICLE SUDDENLY SHUT OFF. THE VEHICLE WAS IN LIMP MODE WHEN THE FAILURE OCCURRED. HE DROVE ONTO THE EMERGENCY LANE AND SHUT THE VEHICLE OFF AND THEN RESTARTED IT. THE VEHICLE WORKED FINE AFTER IT WAS RESTARTED. THE CONTACT CALLED THE MANUF…

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TL*THE CONTACT OWNS A 2005 FORD EXPEDITION. THE CONTACT STATED WHILE DRIVING 70 MPH THE VEHICLE SUDDENLY SHUT OFF. THE VEHICLE WAS IN LIMP MODE WHEN THE FAILURE OCCURRED. HE DROVE ONTO THE EMERGENCY LANE AND SHUT THE VEHICLE OFF AND THEN RESTARTED IT. THE VEHICLE WORKED FINE AFTER IT WAS RESTARTED. THE CONTACT CALLED THE MANUFACTURER REGARDING THE ENGINE AND THE MANUFACTURER ADVISED HER TO TAKE THE VEHICLE TO A DEALER FOR DIAGNOSTIC TESTING. THE CONTACT DID NOT TAKE THE VEHICLE TO THE DEALER FOR DIAGNOSTIC TESTING BECAUSE OF THE COST. THE CONTACT STATED THAT THIS WAS A MAJOR SAFETY ISSUE. THE FAILURE MILEAGE WAS 51,000. THE CONSUMER STATED THE THROTTLE CONTROL UNIT MAY BE A SAFETY PROBLEM, CAUSING SUDDEN LOSS OF ENGINE POWER TO THE VEHICLE. THE LIMP HOME MODE IS AT IDLE SPEED. HOWEVER, WITH THE ENGINE SHUT DOWN, THE VEHICLE STILL HAS POWER BRAKE AND STEERING. THE ENGINE SHUT DOWN CAN OCCUR AT ANYTIME AT ANY SPEED. UPDATED 08/18/11

NHTSA ODI #10398519

83,123 miles · Apr 16, 2011
Fuel System, Other

ME HUSBAND AND I OWN A 2005 FORD EXPEDITION XLT (V8 5.4L). THE TRUCK HAS CUT OFF ON US SEVERAL TIMES IN THE LAST TO WEEKS, WITHOUT WARNING! IT HAS EVEN CUT OFF ON US ON THE HIGHWAY. WE WERE TRAVELING 55MPH. WE HAVE FOUR SMALL CHILDREN THAT TRAVEL WITH US CONSTANTLY. I CONSIDER THIS TO BE A LIFE THREATENING DEFECT. MY HUSBAN…

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ME HUSBAND AND I OWN A 2005 FORD EXPEDITION XLT (V8 5.4L). THE TRUCK HAS CUT OFF ON US SEVERAL TIMES IN THE LAST TO WEEKS, WITHOUT WARNING! IT HAS EVEN CUT OFF ON US ON THE HIGHWAY. WE WERE TRAVELING 55MPH. WE HAVE FOUR SMALL CHILDREN THAT TRAVEL WITH US CONSTANTLY. I CONSIDER THIS TO BE A LIFE THREATENING DEFECT. MY HUSBAND TOOK THE TRUCK TO A MECHANIC, THINKING OH WE JUST NEED A TUNE UP. TWO OF THE SPARK PLUGS BROKE OFF INTO THE MOTOR HEAD. WE ENDED UP SPENDING $800 BUCKS TO HAVE IT REPAIRED AND $150 BUCKS ON A VAN RENTAL. IN MY OPINION FORD SHOULD HANDLE THIS SITUATION AS SOON AS POSSIBLE. IT IS A LIFE THREATENING DEFECT. WE ARE THANKFUL THAT WE MADE IT OFF OF THE HIGHWAY SAFELY THAT DAY. BUT WHAT IF ANOTHER FAMILY HAS THE SAME PROBLEM....AND THEY ARE NOT SO LUCKY? I GUESS FORD WILL THEN ISSUE A RECALL AND EXTEND THEIR MOST SINCERE APOLOGIES. *TR

NHTSA ODI #10396532

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