NHTSA owner reports · September 18, 2026 snapshot.
What owners actually said
315 reports83,500 miles · Dec 16, 2010
Engine And Engine CoolingPower Train
2005 FORD EXPEDITION LIMITED ~83.5K MILES VEHICLE HAD BEEN DRIVEN ABOUT A HALF HOUR AND THE ENGINE STOPPED WITHOUT WARNING, UNABLE TO ACCELERATE, BRAKE OR STEER. COASTED TO SIDE OF ROAD, SHUT VEHICLE OFF, RESTARTED. TOOK TO DEALERSHIP, UNABLE TO REGISTER CODE HOWEVER I PROVIDED THEM WITH COMMENTS FROM ONLINE SITES POINTING TO TH…
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2005 FORD EXPEDITION LIMITED ~83.5K MILES VEHICLE HAD BEEN DRIVEN ABOUT A HALF HOUR AND THE ENGINE STOPPED WITHOUT WARNING, UNABLE TO ACCELERATE, BRAKE OR STEER. COASTED TO SIDE OF ROAD, SHUT VEHICLE OFF, RESTARTED. TOOK TO DEALERSHIP, UNABLE TO REGISTER CODE HOWEVER I PROVIDED THEM WITH COMMENTS FROM ONLINE SITES POINTING TO THROTTLE CONTROL BODY FAILURE CAUSING ENGINE TO GO INTO FAILSAFE MODE. DEALERSHIP'S FIRST INCLINATION WITHOUT ANY CODES IS TO REPLACE A FUEL SENSOR. DEALERSHIP REFUSED TO ADDRESS THROTTLE CONTROL BODY DESPITE MY SUGGESTION ALONG WITH OTHER VEHICLE OWNER'S INCIDENT REPORTS FROM ONLINE SITES. 8 DAYS LATER WHILE MY HUSBAND WAS DRIVING MYSELF AND FIVE CHILDREN, AFTER ABOUT A HALF HOUR OF DRIVING, HE FOUND HE WAS UNABLE TO ACCELERATE, LOOKED AT THE MESSAGE CENTER AND IT SAID CHECK ELECTRONIC THROTTLE CONTROL AT WHICH TIME HE PUT THE VEHICLE IN NEUTRAL AND WAS ABLE TO RESTART. DEALERSHIPS ARE NOT ADDRESSING THIS ISSUE BECAUSE THE ONBOARD COMPUTER OR SENSORS ARE NOT STORING THESE CODES, THE PROBLEM IS SO FAR INTERMITTENT. THIS PARTICULAR DEALERSHIP DESPITE MY RESEARCH WOULD NOT ADDRESS THE ISSUE. IT ALSO APPEARS FORD IS NOT ACKNOWLEDGING THIS EITHER. SO FAR, I HAVE FOUND ONE INSTANCE ONLINE WHERE THE OWNER OF A 2006 EXPEDITION WAS REIMBURSED FROM FORD FOR THE REPLACEMENT OF THEIR ELECTRONIC THROTTLE CONTROL BODY THEREBY ACKNOWLEDGING SOME SEMBLANCE OF RESPONSIBILITY. THIS NEWER THROTTLE CONTROL BODY IS DIFFERENT THAN THE ORIGINAL, IMPROVED. WHY IS THERE NOT A RECALL OR EVEN A TSB? HOW MANY REPORTS OF THERE OUT THERE, HOW MANY ACCIDENTS, INJURIES, POSSIBLY DEATHS MIGHT BE ATTRIBUTED TO THIS FAILURE? AFTER CONTACTING FORD, WE WILL HAVE THE THROTTLE CONTROL BODY REPLACED. ALSO, IT APPEARS, PEOPLE ARE BEING SUGGESTED TO REPLACE THE SENSOR FIRST ONLY TO HAVE THE PROBLEM OCCUR AGAIN - IT'S NOT THE SENSOR, IT'S THE ACTUAL PART. *TR
NHTSA ODI #10370941
60,000 miles · Dec 9, 2010
Electrical System
I OWN A 2005 FORD EXPEDITION AND HAVE EXPERIENCED LOSING ALL THROTTLE CONTROL ON THE FREEWAY. I WAS LUCKY ENOUGH TO MAKE IT SAFELY TO THE SIDE OF THE ROAD. I WAS SCARED . THERE WERE 5 PEOPLE IN THE VEHICLE INCLUDING TWO YOUNG CHILDREN. VERY DANGEROUS! THIS HAPPENS WITHOUT WARNING. AFTER ABOUT 5 MINUTES, THE VEHICLE STARTE…
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I OWN A 2005 FORD EXPEDITION AND HAVE EXPERIENCED LOSING ALL THROTTLE CONTROL ON THE FREEWAY. I WAS LUCKY ENOUGH TO MAKE IT SAFELY TO THE SIDE OF THE ROAD. I WAS SCARED . THERE WERE 5 PEOPLE IN THE VEHICLE INCLUDING TWO YOUNG CHILDREN. VERY DANGEROUS! THIS HAPPENS WITHOUT WARNING. AFTER ABOUT 5 MINUTES, THE VEHICLE STARTED UP AGAIN WITHOUT ANY PROBLEMS. TODAY I HAVE A DIFFERENT PROBLEM. O/D LED FLASHES ON DASH AND VEHICLE WILL NOT ACCELERATE PROPERLY. I HAD IT TOWED TO THE NEAREST MECHANIC. THEY SUSPECT A TRANSMISSION FAULT. I WISH I NEVER DECIDED ON GETTING THIS SUV. I SHOULD NOT BE SCARED TO DRIVE MY CAR. FORD NEEDS TO FIX THIS PROBLEM ASAP!!!!! *TR
NHTSA ODI #10369724
56,000 miles · Nov 30, 2010
Engine And Engine Cooling
TL*THE CONTACT OWNS A 2005 FORD EXPEDITION. WHILE THE CONTACT WAS DRIVING APPROXIMATELY 5 MPH, THE VEHICLE SUDDENLY STOPPED ACCELERATING WITH NO WARNING. THE CONTACT HAD TO TURN THE IGNITION OFF AND ON TO ALLEVIATE THE PROBLEM. THE VEHICLE WAS TAKEN TO A LOCAL REPAIR SHOP BUT THE FAILURE COULD NOT BE DIAGNOSED. THE FAILURE OCCUR…
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TL*THE CONTACT OWNS A 2005 FORD EXPEDITION. WHILE THE CONTACT WAS DRIVING APPROXIMATELY 5 MPH, THE VEHICLE SUDDENLY STOPPED ACCELERATING WITH NO WARNING. THE CONTACT HAD TO TURN THE IGNITION OFF AND ON TO ALLEVIATE THE PROBLEM. THE VEHICLE WAS TAKEN TO A LOCAL REPAIR SHOP BUT THE FAILURE COULD NOT BE DIAGNOSED. THE FAILURE OCCURRED THREE TIMES. THE FAILURE MILEAGE WAS APPROXIMATELY 56,000.
NHTSA ODI #10368389
108,500 miles · Nov 29, 2010
Fuel System, Gasoline
DRIVING AT 50MPH IN 2005 FORD EXPEDITION LMTD. WHEN LOST ALL THROTTLE CONTROL AND HAD TO TRY AND GET TO THE SIDE OF THE ROAD SAFELY. "CHECK THROTTLE CONTROL" WARNING CAME ON DURING INCIDENT. THIS WAS THE FIRST TIME AT 108,500 MILES. IT SEEMS THIS IS HAPPENING A LOT ON THIS VEHICLE MODEL. NOT A VERY SAFE DEFECT FROM FORD. FORD NE…
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DRIVING AT 50MPH IN 2005 FORD EXPEDITION LMTD. WHEN LOST ALL THROTTLE CONTROL AND HAD TO TRY AND GET TO THE SIDE OF THE ROAD SAFELY. "CHECK THROTTLE CONTROL" WARNING CAME ON DURING INCIDENT. THIS WAS THE FIRST TIME AT 108,500 MILES. IT SEEMS THIS IS HAPPENING A LOT ON THIS VEHICLE MODEL. NOT A VERY SAFE DEFECT FROM FORD. FORD NEEDS TO THINK OF THEIR CONSUMER SAFETY AND RECALL AND CORRECT THIS ISSUE. MEANWHILE MY NEXT CAR THAT WAS GOING TO BE A FORD WILL BE SOMETHING DIFFERENT. *TR
NHTSA ODI #10368215
63,000 miles · Nov 18, 2010
Electrical SystemFuel System, GasolineVehicle Speed Control
THIS IS INCIDENT 3 OF 3 WITH RESPECT TO THIS VEHICLE. IN EACH CASE, THE CAR WAS TRAVELING AT A NORMAL RATE OF SPEED UNDER ORDINARY TRAFFIC CONDITIONS. WITHOUT WARNING, THE CAR EITHER LOST POWER AND SHUT OFF SUDDENLY OR LOST THE ABILITY TO ACCELERATE AND SLOWED TO A STOP. IN EACH CASE DASHBOARD MESSAGE CENTER WARNING "CHECK EL…
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THIS IS INCIDENT 3 OF 3 WITH RESPECT TO THIS VEHICLE. IN EACH CASE, THE CAR WAS TRAVELING AT A NORMAL RATE OF SPEED UNDER ORDINARY TRAFFIC CONDITIONS. WITHOUT WARNING, THE CAR EITHER LOST POWER AND SHUT OFF SUDDENLY OR LOST THE ABILITY TO ACCELERATE AND SLOWED TO A STOP. IN EACH CASE DASHBOARD MESSAGE CENTER WARNING "CHECK ELECTRONIC THROTTLE CONTROL" (OR SOMETHING SIMILAR) APPEARED. IN EACH CASE THE DRIVER TURNED THE IGNITION SWITCH TO THE OFF POSITION, WAITED SEVERAL MINUTES, AND THEN STARTED THE CAR. THE WARNING MESSAGE NO LONGER APPEARED AND THE CAR RAN FINE WITHOUT FURTHER IMMEDIATE INCIDENT. IN THIS PARTICULAR CASE (INCIDENT #3), THE CAR WAS TRAVELING AT APPROXIMATELY 25 MPH ON A TWO-LANE (ONE LANE IN EACH DIRECTION) DC CITY STREET. THE CAR LOST POWER COMPLETELY, AND THE DRIVER WAS NOT ABLE TO MOVE THE CAR OUT OF THE LANE OF TRAFFIC, THEREBY BLOCKING THE HEAVY LINE OF TRAFFIC BEHIND HER. AFTER SEVERAL MINUTES, THE DRIVER WAS ABLE TO RESTART THE VEHICLE. *TR
NHTSA ODI #10366744
60,000 miles · Nov 18, 2010
Electrical SystemFuel System, GasolineVehicle Speed Control
THIS IS INCIDENT #2 OF 3 WITH RESPECT TO THIS VEHICLE. IN EACH CASE, THE CAR WAS TRAVELING AT A NORMAL RATE OF SPEED UNDER ORDINARY TRAFFIC CONDITIONS. WITHOUT WARNING, THE CAR EITHER LOST POWER AND SHUT OFF SUDDENLY OR LOST THE ABILITY TO ACCELERATE AND SLOWED TO A STOP. IN EACH CASE DASHBOARD MESSAGE CENTER WARNING "CHECK E…
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THIS IS INCIDENT #2 OF 3 WITH RESPECT TO THIS VEHICLE. IN EACH CASE, THE CAR WAS TRAVELING AT A NORMAL RATE OF SPEED UNDER ORDINARY TRAFFIC CONDITIONS. WITHOUT WARNING, THE CAR EITHER LOST POWER AND SHUT OFF SUDDENLY OR LOST THE ABILITY TO ACCELERATE AND SLOWED TO A STOP. IN EACH CASE DASHBOARD MESSAGE CENTER WARNING "CHECK ELECTRONIC THROTTLE CONTROL" (OR SOMETHING SIMILAR) APPEARED. IN EACH CASE THE DRIVER TURNED THE IGNITION SWITCH TO THE OFF POSITION, WAITED SEVERAL MINUTES, AND THEN STARTED THE CAR. THE WARNING MESSAGE NO LONGER APPEARED AND THE CAR RAN FINE WITHOUT FURTHER IMMEDIATE INCIDENT. IN THIS PARTICULAR CASE (INCIDENT #2), THE CAR WAS TRAVELING AT APPROXIMATELY 60 MPH ON A FOUR-LANE (IN EACH DIRECTION) INTERSTATE HIGHWAY (THE INNER LOOP OF THE CAPITAL BELTWAY IN MONTGOMERY COUNTY, MD). THE DRIVER WAS ABLE TO MOVE THE CAR FROM THE SECOND LANE FROM THE RIGHT TO THE SHOULDER BEFORE LOSING ALL POWER TO ACCELERATE, ALTHOUGH AT RAPIDLY DECELERATING SPEED, THIS MANEUVER WAS EXTREMELY DANGEROUS. WHEN THE CAR WAS NEXT TAKEN TO THE DEALER FOR SERVICE, THE DEALER DID NOT REPORT AN ON-BOARD DIAGNOSTIC CODE THAT WOULD ACCOUNT FOR THIS INCIDENT. *TR
NHTSA ODI #10366741
53,000 miles · Nov 18, 2010
Electrical SystemFuel System, GasolineVehicle Speed Control
THIS IS INCIDENT #1 OF 3 WITH RESPECT TO THIS VEHICLE. IN EACH CASE, THE CAR WAS TRAVELING AT A NORMAL RATE OF SPEED UNDER ORDINARY TRAFFIC CONDITIONS. WITHOUT WARNING, THE CAR EITHER LOST POWER AND SHUT OFF SUDDENLY OR LOST THE ABILITY TO ACCELERATE AND SLOWED TO A STOP. IN EACH CASE DASHBOARD MESSAGE CENTER WARNING "CHECK E…
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THIS IS INCIDENT #1 OF 3 WITH RESPECT TO THIS VEHICLE. IN EACH CASE, THE CAR WAS TRAVELING AT A NORMAL RATE OF SPEED UNDER ORDINARY TRAFFIC CONDITIONS. WITHOUT WARNING, THE CAR EITHER LOST POWER AND SHUT OFF SUDDENLY OR LOST THE ABILITY TO ACCELERATE AND SLOWED TO A STOP. IN EACH CASE DASHBOARD MESSAGE CENTER WARNING "CHECK ELECTRONIC THROTTLE CONTROL" (OR SOMETHING SIMILAR) APPEARED. IN EACH CASE THE DRIVER TURNED THE IGNITION SWITCH TO THE OFF POSITION, WAITED SEVERAL MINUTES, AND THEN STARTED THE CAR. THE WARNING MESSAGE NO LONGER APPEARED AND THE CAR RAN FINE WITHOUT FURTHER IMMEDIATE INCIDENT. IN THIS PARTICULAR CASE (INCIDENT #1), THE CAR WAS TRAVELING AT APPROXIMATELY 35 - 40 MPH ON A THREE-LANE (IN EACH DIRECTION) STATE HIGHWAY. THE DRIVER WAS ABLE TO MOVE THE CAR FROM THE MIDDLE LANE TO THE RIGHT LANE BEFORE LOSING ALL POWER TO ACCELERATE. THIS ROAD HAS NO SHOULDER, SO THE CAR BLOCKED TRAFFIC IN THE RIGHT LANE UNTIL IT WAS RESTARTED. WHEN THE CAR WAS NEXT TAKEN TO THE DEALER FOR SERVICE, THE DEALER DID NOT REPORT AN ON-BOARD DIAGNOSTIC CODE THAT WOULD ACCOUNT FOR THIS INCIDENT. *TR
NHTSA ODI #10366740
38,000 miles · Nov 16, 2010
Engine And Engine Cooling
I FILED A COMPLAINT IN OCT (10355191) REQUESTING INFO ON VEHICLE SHUT DOWN. IT HAPPENED AGAIN THIS WEEK WHILE MY WIFE WAS DRIVING TO WORK. *TR
NHTSA ODI #10365913
82,000 miles · Nov 4, 2010
Vehicle Speed Control
DRIVING APROX. 45 MPH LOSS CONTROL OF THROTTLE 2ND. TIME THIS HAS HAPPENED. *TR
NHTSA ODI #10364072
75,000 miles · Oct 14, 2010
Electrical SystemVehicle Speed Control
2005 FORD EXPEDITION. WHILE DRIVING ON THE HWY THE "CHECK ELECTRONIC THROTTLE CONTROL" LIGHT CAME ON AND SHUT DOWN MY CAR.. I HAD NO ACCELERATOR PEDAL CONTROL. THIS OCCURS ON AVERAGE ONCE A MONTH. WHEN THIS HAPPENS ,YOU HAVE NO POWER. YOU HAVE TO COAST TO THE SIDE OF THE ROAD AND CALL FOR HELP. *TR
NHTSA ODI #10360572
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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