NHTSA owner reports · September 18, 2026 snapshot.
What owners actually said
315 reports62,000 miles · Oct 13, 2010
Power Train
2005 FORD EXPEDITION, TRANSMISSION PROBLEM .WHILE TRAVELING ON A HIGHWAY, THE O/D OFF LIGHT CAME ON. THEN LATER ON , THE CHECK ELECTRONIC THROTTLE POSITION . THE VEHICLE WENT INTO A LIMP HOME MODE. UNSAFE'WHEN I DID INVESTIGATE ,I NOTICED MY VEHICLE WAS LEAKING TRANSMISSION FLUID. THE SPOT WHERE IT WAS LEAKING FROM WAS …
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2005 FORD EXPEDITION, TRANSMISSION PROBLEM .WHILE TRAVELING ON A HIGHWAY, THE O/D OFF LIGHT CAME ON. THEN LATER ON , THE CHECK ELECTRONIC THROTTLE POSITION . THE VEHICLE WENT INTO A LIMP HOME MODE. UNSAFE'WHEN I DID INVESTIGATE ,I NOTICED MY VEHICLE WAS LEAKING TRANSMISSION FLUID. THE SPOT WHERE IT WAS LEAKING FROM WAS NEAR THE RADIATOR, THE TRANSMISSION LINES TO AND FROM THE RADIATOR AND THE EXTERNAL TRANS COOLER AND TRANSMISSION WERE CORRODED. MY REPAIR SHOP TRIED TO OBTAIN AFTERMARKET ONLY TO FIND THEY HAD TO BE SPECIAL ORDERED FROM FORD. WHILE DOING THAT ,FORD INFORMED HIM, THEY HAD SOME 15 KITS COMING IN, HOWEVER THEY WERE ALL ACCOUNTED FOR AND THE NEXT SET WOULD BE IN ANOTHER MONTH. APPARENTLY THERE IS SOMETHING FAULTY. AND DEFINITELY UNSAFE.. *TR
NHTSA ODI #10360333
74,774 miles · Sep 22, 2010
Fuel System, Gasoline
MY 2005 FORD EXPEDITION SUDDENLY STALLED AS I WAS SLOWING DOWN TO ENTER AN INTERSECTION. THE DASH DISPLAYED CHECK ELECTRONIC THROTTLE CONTROL OR ENGINE FAIL SAFE MODE AND THEN I LOST ALL POWER. I QUICKLY STARTED THE TRUCK BACK UP AND WAS ABLE TO DRIVE BACK HOME, BUT HAD ACCELERATION ISSUES ALONG THE WAY AND THE SERVICE ENGINE …
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MY 2005 FORD EXPEDITION SUDDENLY STALLED AS I WAS SLOWING DOWN TO ENTER AN INTERSECTION. THE DASH DISPLAYED CHECK ELECTRONIC THROTTLE CONTROL OR ENGINE FAIL SAFE MODE AND THEN I LOST ALL POWER. I QUICKLY STARTED THE TRUCK BACK UP AND WAS ABLE TO DRIVE BACK HOME, BUT HAD ACCELERATION ISSUES ALONG THE WAY AND THE SERVICE ENGINE LIGHT STAYED ON. FORD SERVICE DEPARTMENT DETERMINED IT WAS THE THROTTLE POSITION SENOR. NO SIGNS PRIOR TO THIS EVENT THAT SOMETHING WAS WRONG WITH THE CAR. APPARENTLY THIS TP SENSOR MALFUNCTION CAUSED ME TO HAVE MY THROTTLE BODY AND FUEL INJECTORS SERVICED TOO. MANY COMPLAINTS ABOUT THE TP SENSOR ON THE INTERNET. THIS ISSUE SEEMS TO BE A HUGE SAFETY ISSUE ESPECIALLY WHEN YOU CONSIDER MOST OF US PURCHASE AN EXPEDITION FOR HAULING AROUND OUR CHILDREN. I HAD MY TWO YEAR OLD IN THE CAR WITH ME WHEN MY TRUCK LOST ALL POWER IN THE MIDDLE OF AN INTERSECTION. *TR
NHTSA ODI #10357030
65,000 miles · Sep 21, 2010
Electrical SystemFuel System, Gasoline
I WAS DRIVING 55MPH ON HIGHWAY, WHEN ALL OF A SUDDEN THERE WAS NO POWER TO GAS PEDAL. THE CHECK ELECTRONIC THROTTLE CONTROL LIGHT FLASHED, I PULLED OVER THREE LANES TO SIDE OF ROAD. I SAT THERE TRYING TO START VEHICLE CONTINUOUSLY, FINALLY AFTER 10 MINUTES IT STARTED. *TR
NHTSA ODI #10356743
37,000 miles · Sep 13, 2010
Electrical SystemEquipment
OUR 2005 FORD EXPEDITION HAS SHUT OFF WITHOUT WARNING TWICE NOW. THE FIRST TIME THIS HAPPENED WE WERE DRIVING BACK FROM MISSOURI TO VIRGINIA AFTER THE HOLIDAYS IN JANUARY OF THIS YEAR. WE WERE ON THE INTERSTATE DRIVING ABOUT 70 MPH WHEN THE CAR JUST STOPPED AND THE CHECK ENGINE LIGHT CAME ON. WE CALLED FORD AND THEY SAID TO L…
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OUR 2005 FORD EXPEDITION HAS SHUT OFF WITHOUT WARNING TWICE NOW. THE FIRST TIME THIS HAPPENED WE WERE DRIVING BACK FROM MISSOURI TO VIRGINIA AFTER THE HOLIDAYS IN JANUARY OF THIS YEAR. WE WERE ON THE INTERSTATE DRIVING ABOUT 70 MPH WHEN THE CAR JUST STOPPED AND THE CHECK ENGINE LIGHT CAME ON. WE CALLED FORD AND THEY SAID TO LET IT SIT FOR 30 MINUTES AND THEN TRY TO START THE CAR AGAIN. WE DID AND IT WORKED. THE TECHNICIAN EXPLAINED THAT IT MAY HAVE BEEN THE COLD WEATHER. JUST YESTERDAY 12 SEPT 2010 MY WIFE WAS DRIVING HOME FROM WORK WHEN THE CAR SHUT OFF ON ITS OWN AGAIN AND THE CHECK ENGINE LIGHT ILLUMINATED. SHE WAITED A FEW MINUTES AND THE CAR STARTED AGAIN. THE COLD HAD NOTHING TO DO WITH IT YESTERDAY. BOTH TIMES WE WERE FORCED TO COAST TO THE SIDE OF THE ROAD IN HEAVY TRAFFIC. LIVING IN THE DC AREA AND USING INTERSTATE 95 ON A SUNDAY AFTERNOON IS ALWAYS A CHALLENGE. HAVING YOUR VEHICLE JUST STOP RUNNING IS INSANE. I AM UNABLE TO FIND ANYTHING ABOUT A RECALL, BUT IN A SEARCH OF THE WEB I FOUND NUMEROUS OWNERS HAVING A SIMILAR ISSUE. WHAT IS FORD DOING ABOUT THIS? *TR
NHTSA ODI #10355191
50,000 miles · Sep 9, 2010
Electrical System
2005 FORD EXPEDITION - ELECTRONIC THROTTLE PROBLEM. THIS HAS BEEN AN ON-GOING PROBLEM SINCE 2008, A VERY DANGEROUS PROBLEM. WILL THE NOTIFICATION WARNS YOU THE CAR DIES IN MID-TRAFFIC CAUSING YOU TO COAST AND THEN THE ENGINE DIES. I HAVE HAD THIS FIXED IN 2008 AND IN 2009 AND 2010 IS HAVING THE SAME ISSUE - SOMEONE WILL END U…
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2005 FORD EXPEDITION - ELECTRONIC THROTTLE PROBLEM. THIS HAS BEEN AN ON-GOING PROBLEM SINCE 2008, A VERY DANGEROUS PROBLEM. WILL THE NOTIFICATION WARNS YOU THE CAR DIES IN MID-TRAFFIC CAUSING YOU TO COAST AND THEN THE ENGINE DIES. I HAVE HAD THIS FIXED IN 2008 AND IN 2009 AND 2010 IS HAVING THE SAME ISSUE - SOMEONE WILL END UP WITH A DEATH DUE TO THIS PROBLEM. PLEASE INVESTIGATE. *TR
NHTSA ODI #10354660
48,000 miles · Aug 30, 2010
Structure
PAINT IS BUBBLING AND PEELING OFF HOOD AND TAILGATE OF 2005 FORD EXPEDITION EDDIE BAUER EDITION. *TR
NHTSA ODI #10352657
87,000 miles · Aug 26, 2010
Fuel System, Other
1.2005 FORD EXPEDITION AUGUST 8,2010: AROUND 12:45PM I STARTED MY CAR UP TO RUN TO MCDONALD'S TWO MINUTES AWAY FROM MY WORK. AS I PULLED OUT OF MCDONALD'S THE CAR STARTED TO SLOW DOWN AND WOULD NOT ACCELERATE. I THOUGHT IT WAS MY GAS SO I PULLED INTO EXXON DOWN THE STREET TO FILL UP ON GAS. I PUT $15 OF GAS INTO THE TANK. WHEN I…
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1.2005 FORD EXPEDITION AUGUST 8,2010: AROUND 12:45PM I STARTED MY CAR UP TO RUN TO MCDONALD'S TWO MINUTES AWAY FROM MY WORK. AS I PULLED OUT OF MCDONALD'S THE CAR STARTED TO SLOW DOWN AND WOULD NOT ACCELERATE. I THOUGHT IT WAS MY GAS SO I PULLED INTO EXXON DOWN THE STREET TO FILL UP ON GAS. I PUT $15 OF GAS INTO THE TANK. WHEN I STARTED TO CAR UP IT IMMEDIATELY STARTED SHAKING VIGOROUSLY AND A STRONG SMELL OF GAS AND CLOUDY FUMES CAME FROM MY EXHAUST PIPE. I HAD TO GO BACK TO WORK SO I DROVE THE TWO MILES WHILE TO CAR STRONGLY SHOOK AND THE EXHAUST PIPE WAS PRODUCING A CLOUD OF SMOKE THAT SMELLED HEAVILY OF GAS. I GOT TO WORK AND CALLED MY HUSBAND. I TURNED OFF THE CAR AND CHECKED MY OIL. I ATTEMPTED TO TURN ON MY CAR AGAIN AND WAS NOT ABLE TO GET MY CAR TO START AGAIN THAT DAY. AT 7PM I ATTEMPTED TO TURN MY CAR ON AGAIN AND IT JUST MADE A LOUD SCREECHY SOUND AND WOULD NOT TURN ON. 2.BECAUSE CAR WOULD NOT START WE CALLED HARRY'S TOWING TO BE TOWED TO A AUTO SHOP NEAREST TO OUR HOME. OUR CAR NEVER BEFORE HAS HAD ANY PROBLEMS AT ALL. 3. WE ASKED THE MECHANIC TO LOOK AT THE CAR AND IDENTIFY THE PROBLEM. WHEN HE CALLED US BACK HE SAID THE FUEL INJECTOR WAS THE PROBLEM AND HE AT THAT TIME HAD REPLACED IT ALREADY AND ADVISED US TO TAKE THE CAR TO FORD DUE TO THE FACT THE HE SAID THE MOTOR WAS DEAD AS WELL. WE THEN HAD THE CAR TOWED TO FORD IN FRANKLIN KENTUCKY. THEY IDENTIFIED THE PROBLEM AS THE FUEL INJECTOR AND THAT THE MOTOR FAILURE WAS DUE TO FUEL INJECTOR PROBLEMS. THE HEADQUARTERS OF FORD SAID WE ARE NOW NOT COVERED UNDER THE EXTENDED WARRANTY DUE TO THE FACT THAT WE TOOK THE CAR TO SOMEONE BESIDES FORD. *TR
NHTSA ODI #10352177
81,800 miles · Aug 19, 2010
Engine And Engine Cooling
TL* THE CONTACT OWNS A 2005 FORD EXPEDITION. WHILE DRIVING 35 MPH, THE CHECK ENGINE WARNING LIGHT ILLUMINATED AND THE VEHICLE BEGAN TO DRIVE ROUGH. THERE WAS ALSO A LARGE QUANTITY OF SMOKE COMING FROM THE TAIL PIPE. THE VEHICLE WAS TOWED TO A LOCAL REPAIR FACILITY WHERE THE CONTACT WAS INFORMED THAT THE FUEL INJECTOR FAILED. THE…
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TL* THE CONTACT OWNS A 2005 FORD EXPEDITION. WHILE DRIVING 35 MPH, THE CHECK ENGINE WARNING LIGHT ILLUMINATED AND THE VEHICLE BEGAN TO DRIVE ROUGH. THERE WAS ALSO A LARGE QUANTITY OF SMOKE COMING FROM THE TAIL PIPE. THE VEHICLE WAS TOWED TO A LOCAL REPAIR FACILITY WHERE THE CONTACT WAS INFORMED THAT THE FUEL INJECTOR FAILED. THE FUEL INJECTOR WAS REPLACED YET THE FAILURE RECURRED. THE DEALER ADVISED THERE WAS A PROBLEM WITH THE CATALYTIC CONVERTER AND RECOMMENDED REPLACING. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 81,800.
NHTSA ODI #10350519
39,000 miles · Aug 12, 2010
Structure
TL*THE CONTACT OWNS A 2005 FORD EXPEDITION. HE STATED THAT THE PAINT ON THE TRUNK AND HOOD OF THE VEHICLE WERE COVERED WITH RUST AND BEGAN PEELING. THE VEHICLE WAS TAKEN TO THE DEALER WHO TOOK PICTURES OF THE VEHICLE AND MAILED THEM TO THE FORD MANUFACTURER. THE MANUFACTURER STATED RESPONDED TO THE PHOTOS STATING THAT THEY WOULD…
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TL*THE CONTACT OWNS A 2005 FORD EXPEDITION. HE STATED THAT THE PAINT ON THE TRUNK AND HOOD OF THE VEHICLE WERE COVERED WITH RUST AND BEGAN PEELING. THE VEHICLE WAS TAKEN TO THE DEALER WHO TOOK PICTURES OF THE VEHICLE AND MAILED THEM TO THE FORD MANUFACTURER. THE MANUFACTURER STATED RESPONDED TO THE PHOTOS STATING THAT THEY WOULD NOT REPAIR THE VEHICLE BECAUSE HE WAS THE SECOND OWNER. THERE WERE NO RELATED RECALLS. THE VIN WAS NOT AVAILABLE. THE FAILURE MILEAGE WAS 39,000.
NHTSA ODI #10349003
Mileage unknown · Aug 10, 2010
Engine And Engine Cooling
TL*THE CONTACT OWNS A 2005 FORD EXPEDITION. THE VEHICLE STALLED WHILE DRIVING AT ANY SPEED. WHEN THE VEHICLE STALLS THE STEERING WHEEL ALSO BECOMES VERY STIFF. DURING THE FAILURE A CHECK ENGINE THROTTLE LIGHT ILLUMINATES ON THE DASHBOARD. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER HE WAS INFORMED EITHER THE THROTTLE OR TH…
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TL*THE CONTACT OWNS A 2005 FORD EXPEDITION. THE VEHICLE STALLED WHILE DRIVING AT ANY SPEED. WHEN THE VEHICLE STALLS THE STEERING WHEEL ALSO BECOMES VERY STIFF. DURING THE FAILURE A CHECK ENGINE THROTTLE LIGHT ILLUMINATES ON THE DASHBOARD. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER HE WAS INFORMED EITHER THE THROTTLE OR THE ENGINE NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS UNKNOWN AND THE CURRENT MILEAGE WAS 112,866.
NHTSA ODI #10348513
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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