NHTSA owner reports · September 18, 2026 snapshot.
What owners actually said
315 reports66,859 miles · Apr 14, 2011
Fuel System, Gasoline
TL* THE CONTACT OWNS A 2005 FORD EXPEDITION. THE CONTACT WAS DRIVING APPROXIMATELY 10 MPH WHEN THE ENGINE STALLED WITHOUT PRIOR WARNING. THE ENGINE FAILED TO RESTART AND THE VEHICLE WAS TOWED AN AUTHORIZED DEALER WHERE THE FUEL PUMP DRIVER MODULE WAS REPLACED. THE FAILURE MILEAGE WAS 66,859. UPDATED 05/05/11*LJ THE CONSUMER STA…
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TL* THE CONTACT OWNS A 2005 FORD EXPEDITION. THE CONTACT WAS DRIVING APPROXIMATELY 10 MPH WHEN THE ENGINE STALLED WITHOUT PRIOR WARNING. THE ENGINE FAILED TO RESTART AND THE VEHICLE WAS TOWED AN AUTHORIZED DEALER WHERE THE FUEL PUMP DRIVER MODULE WAS REPLACED. THE FAILURE MILEAGE WAS 66,859. UPDATED 05/05/11*LJ THE CONSUMER STATED WHEN THE ENGINE FAILED, HE LOST POWER STEERING. HE WAS ON STEEP HILL AND WAS ABLE TO STOP BY PLACING THE TRUCK INTO PARK AND APPLYING THE EMERGENCY BRAKE. UPDATED 07/01/11
NHTSA ODI #10395916
70,000 miles · Apr 14, 2011
Electrical SystemVehicle Speed Control
TL* THE CONTACT OWNS A 2005 FORD EXPEDITION. WHILE DRIVING AT VARIOUS SPEEDS, THE CONTACT HEARD A BEEPING NOISE AND THEN NOTICED THAT THE CHECK ELECTRONIC THROTTLE WARNING LIGHT WAS ILLUMINATED AS THE VEHICLE LOST POWER. THE FAILURE RECURRED ON FOUR SEPARATE OCCASIONS. THE VEHICLE WAS TOWED TO A PRIVATE MECHANIC WHO ADVISED THE …
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TL* THE CONTACT OWNS A 2005 FORD EXPEDITION. WHILE DRIVING AT VARIOUS SPEEDS, THE CONTACT HEARD A BEEPING NOISE AND THEN NOTICED THAT THE CHECK ELECTRONIC THROTTLE WARNING LIGHT WAS ILLUMINATED AS THE VEHICLE LOST POWER. THE FAILURE RECURRED ON FOUR SEPARATE OCCASIONS. THE VEHICLE WAS TOWED TO A PRIVATE MECHANIC WHO ADVISED THE CONTACT THAT THE ELECTRONIC CONTROL MODULE HAD FAILED. HE REMOVED THE BATTERY TERMINAL, RESET THE COMPUTER, CLEARED ALL CODES, REPLACED THE THROTTLE POSITION CENSOR, AND CLEANED THE THROTTLE BODY. THE DEALER WAS NOTIFIED OF THE PREVIOUS FAILURES AND DID NOT OFFER ANY ASSISTANCE. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE CURRENT MILEAGE WAS 110,000 AND THE FAILURE MILEAGE WAS 70,000. THE VIN WAS UNAVAILABLE. UPDATED 04/25/11 *BF THE CONSUMER STATED THE PROBLEM HAPPENED FOR A SECOND TIME. UPDATED 06/20/11
NHTSA ODI #10395906
63,000 miles · Mar 28, 2011
Fuel System, Gasoline
MY 2005 FORD EXPEDITION HAS BEEN EXPERIENCING INTERMITTENT PROBLEMS AND THE ONLY MESSAGE YOU RECEIVE IS "CHECK ELECTRONIC FUEL THROTTLE." TRAVELING AT ANY SPEED THE CAR LOSES POWER IN THE SENSE LIKE IT HAS BEEN SHIFTED INTO NEUTRAL. WHEN THIS OCCURS YOU CAN STEP ON THE GAS PEDAL BUT ITS LIKE IT ISN'T ACKNOWLEDGED. YOU SHUT TH…
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MY 2005 FORD EXPEDITION HAS BEEN EXPERIENCING INTERMITTENT PROBLEMS AND THE ONLY MESSAGE YOU RECEIVE IS "CHECK ELECTRONIC FUEL THROTTLE." TRAVELING AT ANY SPEED THE CAR LOSES POWER IN THE SENSE LIKE IT HAS BEEN SHIFTED INTO NEUTRAL. WHEN THIS OCCURS YOU CAN STEP ON THE GAS PEDAL BUT ITS LIKE IT ISN'T ACKNOWLEDGED. YOU SHUT THE CAR OFF WAIT A FEW MINUTES AND RESTART IT AND EVERYTHING IS FINE. YOU MAY GO DAYS OR IT MAY BE WEEKS BEFORE IT HAPPENS AGAIN. IT IS A VERY SCARY SITUATION WHEN THIS HAPPENS. I HAVE BEEN SO LUCKY NOT TO HAVE BEEN INVOLVED IN AN ACCIDENT DUE TO THIS PROBLEM.
NHTSA ODI #10394505
73,000 miles · Mar 24, 2011
Vehicle Speed Control
TL* THE CONTACT OWNS A 2005 FORD EXPEDITION. THE CONTACT STATED WHILE DRIVING 35 MPH, THE ELECTRONIC THROTTLE CONTROL WARNING LIGHT WAS ILLUMINATED AND THE VEHICLE IMMEDIATELY STALLED. THE CONTACT STATED THAT THE FAILURE WOULD RECUR WHEN DRIVING ANY SPEED. THE VEHICLE WOULD RESTART IMMEDIATELY AND DRIVE AS NORMAL. THE DEALER WA…
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TL* THE CONTACT OWNS A 2005 FORD EXPEDITION. THE CONTACT STATED WHILE DRIVING 35 MPH, THE ELECTRONIC THROTTLE CONTROL WARNING LIGHT WAS ILLUMINATED AND THE VEHICLE IMMEDIATELY STALLED. THE CONTACT STATED THAT THE FAILURE WOULD RECUR WHEN DRIVING ANY SPEED. THE VEHICLE WOULD RESTART IMMEDIATELY AND DRIVE AS NORMAL. THE DEALER WAS CONTACTED AND STATED THAT THE THROTTLE BODY WOULD POSSIBLY NEED REPLACING AT A COST OF $600. THERE WERE NO RECALLS OR WARRANTIES FOR THE FAILURE. THE MANUFACTURER WAS NOT CONTACTED. THE FAILURE MILEAGE WAS 73,000 AND THE CURRENT MILEAGE WAS 98,000.
NHTSA ODI #10392731
60,000 miles · Mar 11, 2011
Electrical System
CARS SHUTS OFF WHILE DRIVING! I HAVE EXPERIENCE THIS FOUR TIMES AT VARIOUS SPEEDS. THE CAR SHUTS OFF AND THE CHECK ELECTRONIC THROTTLE CONTROL LIGHT COMES ON. TWICE HAVE BEEN ON THE FREEWAY AT 65 MILES PER HOUR WITHOUT WARNING. BOTH TIMES I WAS ABLE TO START ENGINE BY PUTTING IT IN NEUTRAL WHILE DRIVING. ALTHOUGH I WOULD NOT…
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CARS SHUTS OFF WHILE DRIVING! I HAVE EXPERIENCE THIS FOUR TIMES AT VARIOUS SPEEDS. THE CAR SHUTS OFF AND THE CHECK ELECTRONIC THROTTLE CONTROL LIGHT COMES ON. TWICE HAVE BEEN ON THE FREEWAY AT 65 MILES PER HOUR WITHOUT WARNING. BOTH TIMES I WAS ABLE TO START ENGINE BY PUTTING IT IN NEUTRAL WHILE DRIVING. ALTHOUGH I WOULD NOT RECOMMEND PERFORMING THIS TECHNIQUE AS YOU MAY ACCIDENTALLY PUT THE CAR INTO REVERSE AND AT THAT SPEED IT COULD BE RISKY. HOWEVER, I HAD NO CHOICE BECAUSE OF THE LANE I WAS IN. AS MOST HAVE MENTIONED, THIS IS SERIOUS PROBLEM ESPECIALLY WHEN DRIVING WITH FAMILY IN VEHICLE. MY WIFE WILL NOT DRIVE THE CAR BECAUSE SHE'S AFRAID...I DON'T BLAME HER. FORD SELLS ITSELF AS A FAMILY ORIENTED COMPANY SO LETS PROTECT OUR FAMILIES AND FIX THE PROBLEM. THESE COMPLAINTS DATE AS FAR BACK AS 2005. ARE THEY WAITING UNTIL SOME OF THEIR CUSTOMERS START GETTING IN SERIOUS ACCIDENTS? THIS IS A LIFE THREATENING PROBLEM AND NEEDS TO BE ADDRESSED! IF THEY DO NOT WANT TO PERFORM A RECALL THEN THEY SHOULD AT LEAST TELL US HOW TO FIX IT SINCE THEIR DEALERS ARE NOT. *TR
NHTSA ODI #10389895
122,000 miles · Mar 10, 2011
Fuel System, Gasoline
WHILE DRIVING MY 2005 FORD EXPEDITION UNDER NORMAL DRIVING CONDITION AT APPROXIMATELY 35 MILES PER HOUR, THE "CHECK ELECTRONIC THROTTLE CONTROL" INDICATOR APPEARED ON THE DASH CONSOLE AND THE ENGINE SHUT OFF. I PUT THE VEHICLE IN NEUTRAL GEAR AND COASTED TO A STOP ON A SIDE ROAD. THE VEHICLE RESTARTED WITH NO ISSUE AND I WAS ABL…
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WHILE DRIVING MY 2005 FORD EXPEDITION UNDER NORMAL DRIVING CONDITION AT APPROXIMATELY 35 MILES PER HOUR, THE "CHECK ELECTRONIC THROTTLE CONTROL" INDICATOR APPEARED ON THE DASH CONSOLE AND THE ENGINE SHUT OFF. I PUT THE VEHICLE IN NEUTRAL GEAR AND COASTED TO A STOP ON A SIDE ROAD. THE VEHICLE RESTARTED WITH NO ISSUE AND I WAS ABLE TO CONTINUE ON MY TRIP. THIS HAS HAPPENED ENUMERABLE TIMES WITH THIS VEHICLE. MY WIFE, SON AND I ALL KNOW THE DRILL. WHY HASN'T FORD PUT A SERVICE BULLETIN OUT ON THIS ISSUE? *TR
NHTSA ODI #10389724
125,000 miles · Feb 9, 2011
Electrical System
DRIVING AT 45 MPH VEHICLE JUST TURNS OFF AND HAS NO POWER. HARD TO STEER AND BRAKE. DASH SAYS "CHECK ELECTRONIC THROTTLE CONTROL". AFTER PULLING OVER VEHICLE WILL RESTART. THIS HAS HAPPENED THREE TIMES NOW AND DEALER SAYS THERE IS NOTHING WRONG. *TR
NHTSA ODI #10381357
92,000 miles · Feb 7, 2011
Vehicle Speed Control
TL*THE CONTACT OWNS A 2005 FORD EXPEDITION EDDIE BAUER EDITION(NA). WHILE DRIVING 10-20 MPH, THE ELECTRONIC THROTTLE CONTROL LIGHT ILLUMINATED ON THE INSTRUMENT PANEL. THE VEHICLE STALLED AND THE CONTACT COASTED THE VEHICLE TO THE SIDE OF THE ROAD. AFTER A FEW MINUTES, THE VEHICLE WAS RESTARTED AND FUNCTIONED PROPERLY. THE LIGHT…
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TL*THE CONTACT OWNS A 2005 FORD EXPEDITION EDDIE BAUER EDITION(NA). WHILE DRIVING 10-20 MPH, THE ELECTRONIC THROTTLE CONTROL LIGHT ILLUMINATED ON THE INSTRUMENT PANEL. THE VEHICLE STALLED AND THE CONTACT COASTED THE VEHICLE TO THE SIDE OF THE ROAD. AFTER A FEW MINUTES, THE VEHICLE WAS RESTARTED AND FUNCTIONED PROPERLY. THE LIGHT ON THE INSTRUMENT PANEL TURNED OFF AS WELL. THE VEHICLE WAS TAKEN TO A LOCAL REPAIR SHOP WHERE THE CONTACT WAS INFORMED THAT THE THROTTLE SENSOR NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED. THE FAILURE OCCURRED AGAIN. THE VEHICLE HAD NOT BEEN REPAIRED. THE FAILURE MILEAGE WAS 92,000 AND THE CURRENT MILEAGE WAS 94,000.
NHTSA ODI #10381010
65,000 miles · Feb 4, 2011
Fuel System, Gasoline
I OWN A 2005 FORD EXPEDITION. THIS YEAR MODEL EXPEDITION HAS A KNOWN THROTTLE CONTROL ISSUE THAT CAUSES THE VEHICLE'S ENGINE TO DEFAULT TO "FAILSAFE MODE," WHICH IS A REDUCED POWER MODE. THIS IS A VERY SIGNIFICANT SAFETY ISSUE BECAUSE "FAILSAFE MODE" CAN BE ACTIVATED ANYWHERE AT ANY TIME WITHOUT WARNING. IMAGINE THE IMPLICATIONS…
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I OWN A 2005 FORD EXPEDITION. THIS YEAR MODEL EXPEDITION HAS A KNOWN THROTTLE CONTROL ISSUE THAT CAUSES THE VEHICLE'S ENGINE TO DEFAULT TO "FAILSAFE MODE," WHICH IS A REDUCED POWER MODE. THIS IS A VERY SIGNIFICANT SAFETY ISSUE BECAUSE "FAILSAFE MODE" CAN BE ACTIVATED ANYWHERE AT ANY TIME WITHOUT WARNING. IMAGINE THE IMPLICATIONS OF SUDDENLY LOSING MOST OF YOUR ENGINE'S POWER AT INTERSTATE OR HIGHWAY SPEEDS. NOW, IMAGINE THE SAME SCENARIO WITH YOUR FAMILY ON BOARD AND A BOAT IN TOW, A VERY COMMON USE FOR THIS TYPE OF VEHICLE. THE INTERNET IS FULL OF FAILED THROTTLE BODY COMPLAINTS, YET FORD HAS DONE NOTHING TO ADDRESS THIS POTENTIALLY LIFE THREATENING DEFECT. THIS IS MUCH MORE THAN A NUISANCE ISSUE THAT THREATENS ONLY THE OWNERS' POCKETBOOKS. THIS IS A MAJOR SAFETY HAZARD AND FORD NEEDS TO DO SOMETHING ABOUT IT. THEIR NEGLIGENCE IS SHAMEFUL. *TR
NHTSA ODI #10380217
83,000 miles · Jan 25, 2011
Electrical SystemPower Train
I WAS DRIVING UP THE HIGHWAY WITH MY TWO KIDS IN MY CAR. I WAS TRAVELING ABOUT 40 MPH. ALL OF A SUDDEN I HEAR THE BEEP ON MY SYSTEM AND IT STATED THAT I NEEDED TO " CHECK ELECTRONIC THROTTLE CONTROL". I LAID OFF THE GAS AND WENT THRU A LIGHT WHEN I ATTEMPTED TO HIT THE GAS AGAIN I REALIZED I HAD NO POWER AT ALL AND I WAS COAST…
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I WAS DRIVING UP THE HIGHWAY WITH MY TWO KIDS IN MY CAR. I WAS TRAVELING ABOUT 40 MPH. ALL OF A SUDDEN I HEAR THE BEEP ON MY SYSTEM AND IT STATED THAT I NEEDED TO " CHECK ELECTRONIC THROTTLE CONTROL". I LAID OFF THE GAS AND WENT THRU A LIGHT WHEN I ATTEMPTED TO HIT THE GAS AGAIN I REALIZED I HAD NO POWER AT ALL AND I WAS COASTING. I GOT IN THE TURNING LANE AND HAD TO PULL IN FRONT OF A CAR JUST SO I WOULD NOT BE STUCK IN THE MIDDLE OF THE ROAD WHERE MY KIDS AND I WOULD HAVE BEEN IN AN ACCIDENT. I WAITED ABOUT 10 MINUTES AND THE VEHICLE FIRED UP. I WAS IN TEARS TRYING TO MAKE IT TO MY OFFICE BECAUSE I FELT LIKE IT MIGHT HAPPEN AGAIN. THE WHOLE MILE IT TOOK FOR ME TO GET THERE THE TRUCK FELT LIKE IT WAS GOING TO SHUT OFF AGAIN. IT FELT LIKE THE TRUCK DID NOT HAVE GAS AND WAS RIDING ON FUMES. IT WAS SHAKING AND MOVING SLOWING. I WILL NOT DRIVE IT LIKE THIS AND WILL PROBABLY TRADE IT IN NOW. I CANNOT DRIVE A VEHICLE THAT I DO NOT FEEL IS RELIABLE FOR ME AND MY KIDS. THIS IS THE FIRST TIME THAT THIS HAS HAPPENED AND THE TRUCK HAS 83K MILES ON IT. I ALSO HAD PROBLEMS WITH THE CATALYTIC CONVERTER AT 46K MILES. MY MECHANIC SAID THAT THE THROTTLE BODY COULD HAVE FAILED AS A RESULT OF THE CATALYTIC CONVERTER NOT WORKING PROPERLY. I MIGHT TRY TO FIX THE PROBLEM DEPENDING ON COSTS ASSOCIATED WITH IT OR MIGHT GET ANOTHER VEHICLE. *TR
NHTSA ODI #10378596
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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