NHTSA owner reports · September 18, 2026 snapshot.
What owners actually said
315 reports65,000 miles · Jun 30, 2010
Vehicle Speed Control
TL* THE CONTACT OWNS A 2005 FORD EXPEDITION. WHILE TRAVELING 45 MPH HE CONTACT NOTICED THAT THE CHECK ELECTRONIC THROTTLE CONTROL LIGHT HAD APPEARED ON THE INSTRUMENT PANEL , SECONDS LATER THE VEHICLE HAD SUDDENLY SHUT OFF. THE VEHICLE WAS RESTARTED AND TAKEN TO THE DEALERSHIP WHERE THE THROTTLE BODY WAS REPLACED. THERE WERE NO …
Read full complaint
TL* THE CONTACT OWNS A 2005 FORD EXPEDITION. WHILE TRAVELING 45 MPH HE CONTACT NOTICED THAT THE CHECK ELECTRONIC THROTTLE CONTROL LIGHT HAD APPEARED ON THE INSTRUMENT PANEL , SECONDS LATER THE VEHICLE HAD SUDDENLY SHUT OFF. THE VEHICLE WAS RESTARTED AND TAKEN TO THE DEALERSHIP WHERE THE THROTTLE BODY WAS REPLACED. THERE WERE NO PRIOR WARNINGS. THE CURRENT AND FAILURE MILEAGES WAS 65000.
NHTSA ODI #10340758
31,500 miles · Jun 10, 2010
Engine And Engine Cooling
TL*THE CONTACT OWNS A 2005 FORD EXPEDITION. WHILE DRIVING 50-55 MPH THE VEHICLE STALLED IN THE MIDDLE OF THE ROAD AND THE CHECK ELECTRONIC THROTTLE WARNING LIGHT ILLUMINATED ON THE INSTRUMENT PANEL. SHE WAITED A FEW SECONDS AND TURNED THE VEHICLE BACK ON AND IT BEGAN TO FUNCTION NORMALLY. THE FAILURE OCCURRED TWICE. THE VEHICLE …
Read full complaint
TL*THE CONTACT OWNS A 2005 FORD EXPEDITION. WHILE DRIVING 50-55 MPH THE VEHICLE STALLED IN THE MIDDLE OF THE ROAD AND THE CHECK ELECTRONIC THROTTLE WARNING LIGHT ILLUMINATED ON THE INSTRUMENT PANEL. SHE WAITED A FEW SECONDS AND TURNED THE VEHICLE BACK ON AND IT BEGAN TO FUNCTION NORMALLY. THE FAILURE OCCURRED TWICE. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER WHO WAS UNABLE TO DIAGNOSE OR DUPLICATE THE FAILURE. THE FAILURE MILEAGE WAS 31,500 AND THE CURRENT MILEAGE WAS 31,750.
NHTSA ODI #10335630
47,000 miles · Jun 2, 2010
Power Train
DRIVING MY 2005 FORD EXPEDITION LIMITED IN THE MORNING. AFTER ABOUT 2 MILES THE CAR POWERED TO A CRAWL AND GAVE ENGINE FAIL SAFE MODE ALERT. PULLED TO SIDE. POWERED DOWN CAR AND THE RESTARTED WITHOUT INCIDENT. A WEEK LATER THE SAME THING HAPPENED AGAIN. THIS IS APPARENTLY A DEFECTIVE THROTTLE CONTROL UNIT. THIS DESCRIPTION…
Read full complaint
DRIVING MY 2005 FORD EXPEDITION LIMITED IN THE MORNING. AFTER ABOUT 2 MILES THE CAR POWERED TO A CRAWL AND GAVE ENGINE FAIL SAFE MODE ALERT. PULLED TO SIDE. POWERED DOWN CAR AND THE RESTARTED WITHOUT INCIDENT. A WEEK LATER THE SAME THING HAPPENED AGAIN. THIS IS APPARENTLY A DEFECTIVE THROTTLE CONTROL UNIT. THIS DESCRIPTION IS ALL OVER THE INTERNET AND IS A KNOWN SAFETY PROBLEM AS PEOPLE ARE REPORTING THAT IT HAS HAPPENED TO THEM ON THE FREEWAY. CAR IS UNSAFE TO DRIVE AND EVEN THOUGH THE PROBLEM IS WELL KNOWN, FORD COMPANY IS TAKING NO RESPONSIBILITY. ALL NHTSA HAS TO DO IS GOOGLE "ENGINE FAIL SAFE MODE" AND SEE THE NUMBER OF PROBLEMS THAT COME UP WITH SAME ISSUE. THIS IS DEFINITELY A WELL KNOWN SAFETY PROBLEM BUT YET THERE IS NO RECALL. DEALER SAYS THROTTLE CONTROL UNIT HAS TO BE REPLACED AT A COST OF $514.61 + TAX. THIS PROBLEM MAY ALSO HAVE TAKEN OUT MY AIR CONDITIONING. IT WENT OUT AT THE SAME TIME AS THE SECOND FAILURE, BUT DEALER (VISTA FORD IN OXNARD) IS SAYING THERE IS NO RELATIONSHIP. OTHERS HAVE REPORTED A/C SHUTTING DOWN WHEN ENGINE FAIL SAFE FAILURE OCCURRED. *TR
NHTSA ODI #10334316
41,000 miles · May 11, 2010
Fuel System, Other
2005 FORD EXPEDITION STOPPED RUNNING WHILE DRIVING AT 40 MPH IN HEAVY TRAFFIC. VEHICLE WOULD NOT RESTART. IT APPEARS TO BE A FUEL PUMP PROBLEM. ONLY 40,000 MILES ON THIS VEHICLE. NONE OF THE DASH BOARD LIGHT INDICATORS CAME ON. *TR
NHTSA ODI #10330000
96,000 miles · Apr 25, 2010
Engine And Engine Cooling
ORIGINAL FACTORY SPARK PLUG BACKED OUT FROM CYLINDER HEAD. CHECKED REMAINING 7 SPARK PLUGS. FOUR OF SEVEN LOOSE. MECHANIC RECOMMENDED USING HELI COIL KIT ON ALL SPARK PLUG THREADS. MECHANIC MENTIONED THAT THIS WAS A COMMON OCCURRENCE ON FORD 5.4 LITER ENGINES. IF THIS IS TRUE, IT APPEARS AS THOUGH A RECALL SHOULD BE REQUIRED FOR…
Read full complaint
ORIGINAL FACTORY SPARK PLUG BACKED OUT FROM CYLINDER HEAD. CHECKED REMAINING 7 SPARK PLUGS. FOUR OF SEVEN LOOSE. MECHANIC RECOMMENDED USING HELI COIL KIT ON ALL SPARK PLUG THREADS. MECHANIC MENTIONED THAT THIS WAS A COMMON OCCURRENCE ON FORD 5.4 LITER ENGINES. IF THIS IS TRUE, IT APPEARS AS THOUGH A RECALL SHOULD BE REQUIRED FOR REPAIR OF CYLINDER HEADS. *TR
NHTSA ODI #10327351
94,189 miles · Apr 22, 2010
Engine And Engine Cooling
MY 2005 FORD EXPEDITION WAS CUTTING OFF AND TICKING EVERYDAY, BUT NO LIGHTS WERE COMING ON TO TELL ME WHAT IT WAS, I TOOK MY VEHICLE TO PEP BOYS SHOP AND THEY DECLINE TO FIX IT DO TO SPARK PLUGS BREAKING IN THE ENGINE, SO I TOOK IT TO THE FORD DEALER WHERE I PURCHASED IT. IT TOOK THEM A WHOLE DAY TO FIGURE OUT WHAT WAS WRONG WIT…
Read full complaint
MY 2005 FORD EXPEDITION WAS CUTTING OFF AND TICKING EVERYDAY, BUT NO LIGHTS WERE COMING ON TO TELL ME WHAT IT WAS, I TOOK MY VEHICLE TO PEP BOYS SHOP AND THEY DECLINE TO FIX IT DO TO SPARK PLUGS BREAKING IN THE ENGINE, SO I TOOK IT TO THE FORD DEALER WHERE I PURCHASED IT. IT TOOK THEM A WHOLE DAY TO FIGURE OUT WHAT WAS WRONG WITH IT, THEY SAID I NEEDED A TUNE UP WHICH WAS $279, AND HE TOLD ME THAT ALL OF SPARK PLUGS NEEDED TO BE REPLACED AND THAT THEY SOMETIMES BREAK OFF IN THE ENGINE AND IF THAT WHERE TO HAPPEN IT WOULD BE A ADDITIONAL $90 PER PLUG, THE COIL NEEDED TO REPLACED $95, AND THE ON OF THE CYLINDER NEED TO BE REPLACED UNKNOWN AMOUNT/FORGOT, THEN THEY CALL ME BACK AND TOLD ME THAT ALL OF THE SPARK PLUGS HAD BROKE. THE FORD DEALERSHIP REPAIRED MY TRUCK CAUSE THERE WHERE OTHER PROBLEMS AS WELL SO TOTAL $1000 IN REPAIRS FOR A PROBLEM THAT I NEVER NEW THIS TRUCK WAS HAVING. *TR
NHTSA ODI #10327018
70,000 miles · Apr 22, 2010
Electrical System
MY 2005 FORD EXPEDITION WILL SUDDENLY TURN OFF WHILE IN MOTION WITH NO WARNING. THERE IS NO PATTERN TO DETERMINE WHEN IT WILL TURN OFF. IN THE 6 MONTHS I HAVE OWNED THE VEHICLE, IT HAS TURNED OFF CLOSE TO A DOZEN TIMES, AT SPEEDS RANGING FROM 20 MILES AN HOUR TO FULL FREEWAY SPEED. THE ELECTRONIC THROTTLE CONTROL LIGHT TURNS ON.…
Read full complaint
MY 2005 FORD EXPEDITION WILL SUDDENLY TURN OFF WHILE IN MOTION WITH NO WARNING. THERE IS NO PATTERN TO DETERMINE WHEN IT WILL TURN OFF. IN THE 6 MONTHS I HAVE OWNED THE VEHICLE, IT HAS TURNED OFF CLOSE TO A DOZEN TIMES, AT SPEEDS RANGING FROM 20 MILES AN HOUR TO FULL FREEWAY SPEED. THE ELECTRONIC THROTTLE CONTROL LIGHT TURNS ON. I HAVE TAKEN IT TO A REPUTABLE MECHANIC WHO WAS UNABLE TO REPLICATE THE PROBLEM AS THE CODE REPORTED THAT THE ERROR OCCURRED WHILE THE VEHICLE WAS TURNED OFF - WHICH IS TECHNICALLY IMPOSSIBLE. RESEARCH HAS SHOWN THIS IS A COMMON PROBLEM WITH THIS VEHICLE, AND IT IS OBVIOUSLY DANGEROUS FOR A VEHICLE TO TURN OFF WHILE IT IS IN MOTION. I WOULD HOPE THIS VEHICLE IS RECALLED BEFORE INFORMATION LEAKS THAT PEOPLE HAVE DIED AS A RESULT. *TR
NHTSA ODI #10326986
90,000 miles · Apr 13, 2010
Power Train
2005 FORD EXPEDITION "ELECTRONIC THROTTLE CONTROL" LIGHT WILL COME ON AND THE ENGINE WILL STALL. THIS WILL HAPPEN AT ANY TIME, ANY SPEED AND WITHOUT WARNING. UNFORTUNATELY SOMEONE WILL HAVE TO BE SEVERELY INJURED BEFORE FORD TAKES A LOOK AT THIS. *TR
NHTSA ODI #10325452
45,000 miles · Apr 11, 2010
Electrical System
WHILE DRIVING MY FORD 2005 EXPEDITION THE CAR STOPS RESPONDING TO THE THROTTLE AND LOSSES ALL POWER. THE DASHBOARD WARNING SYSTEM DISPLAYS "CHECK ELECTRONIC THROTTLE CONTROL". AFTER SHUTTING THE ENGINE OFF AND WAITING SEVERAL MINUTES THE CAR CAN BE RESTARTED AND DRIVEN. WE HAVE INQUIRED ABOUT THIS ISSUE WITH NO SATISFACTION. *TR…
Read full complaint
WHILE DRIVING MY FORD 2005 EXPEDITION THE CAR STOPS RESPONDING TO THE THROTTLE AND LOSSES ALL POWER. THE DASHBOARD WARNING SYSTEM DISPLAYS "CHECK ELECTRONIC THROTTLE CONTROL". AFTER SHUTTING THE ENGINE OFF AND WAITING SEVERAL MINUTES THE CAR CAN BE RESTARTED AND DRIVEN. WE HAVE INQUIRED ABOUT THIS ISSUE WITH NO SATISFACTION. *TR
NHTSA ODI #10324956
69,000 miles · Apr 11, 2010
Fuel System, GasolineVehicle Speed Control
2005 FORD EXPEDITION WITHOUT WARNING STALLED WHILE MAKING A RIGHT HAND TURN AT AN INTERSECTION. VEHICLE TAKEN TO DEALERSHIP AND INFORMED ELECTRONIC THROTTLE BODY NEEDED TO BE REPLACED. VEHICLE ONLY HAS 60,000 MILES. INFORMED BY DEALERSHIP REASONS FOR DEFECT UNKNOW. HOWEVER, WE WERE STILL RESPONSIBLE FOR ALL REPAIR COSTS. REV…
Read full complaint
2005 FORD EXPEDITION WITHOUT WARNING STALLED WHILE MAKING A RIGHT HAND TURN AT AN INTERSECTION. VEHICLE TAKEN TO DEALERSHIP AND INFORMED ELECTRONIC THROTTLE BODY NEEDED TO BE REPLACED. VEHICLE ONLY HAS 60,000 MILES. INFORMED BY DEALERSHIP REASONS FOR DEFECT UNKNOW. HOWEVER, WE WERE STILL RESPONSIBLE FOR ALL REPAIR COSTS. REVIEW OF INTERNET INDICATES SEVERAL FORD CUSTOMERS HAVE REPORTED SAME PROBLEM WITH EXACT YEAR AND MAKE OF VEHICLE. *TR
NHTSA ODI #10324936
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
Illustration