NHTSA owner reports · September 18, 2026 snapshot.
What owners actually said
315 reports72,000 miles · Apr 6, 2010
Engine And Engine Cooling
MY 2005 FORD EXPEDITION SUDDENLY AND UNEXPECTEDLY SHUT OFF IN THE MIDDLE OF THE HIGHWAY. AN ERROR CODE OF "CHECK ELECTRONIC THROTTLE" DISPLAYS ON THE DASH AND A WARNING SIGNAL SOUNDS. ALL WHILE THE VEHICLE LOSES THE ABILITY TO ACCELERATE AND POWER STEERING. AFTER BRINGING THE VEHICLE TO A STOP, IT CRANKS RIGHT UP AS IF THERE WAS…
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MY 2005 FORD EXPEDITION SUDDENLY AND UNEXPECTEDLY SHUT OFF IN THE MIDDLE OF THE HIGHWAY. AN ERROR CODE OF "CHECK ELECTRONIC THROTTLE" DISPLAYS ON THE DASH AND A WARNING SIGNAL SOUNDS. ALL WHILE THE VEHICLE LOSES THE ABILITY TO ACCELERATE AND POWER STEERING. AFTER BRINGING THE VEHICLE TO A STOP, IT CRANKS RIGHT UP AS IF THERE WAS NEVER A PROBLEM. IT HAS NOW DONE THIS ABOUT 5 OR 6 TIMES. WE HAVE NEARLY BEEN HIT TWICE BY 18 WHEELERS AS A RESULT OF THIS. THIS IS AN EXTREMELY DANGEROUS PROBLEM. I HAVE RESEARCHED THE PROBLEM ONLINE IN HOPES OF FINDING OUT WHAT COULD BE CAUSING THE PROBLEM. TO MY HORROR, I FOUND HUNDREDS OF SIMILAR COMPLAINTS ALL LINKED TO THE 2005 FORD EXPEDITION ONLY. I HAVE NOT SEEN THIS TYPE OF COMPLAINT FOR ANY OTHER MODEL YEAR. I'M LEARY OF EVEN TAKING IT TO A DEALERSHIP FOR THE PROBLEM AT THIS POINT BECAUSE THE COMMENTS AROUND THE ISSUES HAVE BEEN THAT FORD HAS REPLACED THE "THROTTLE BODY" AND IN SOME CASES IT DIDN'T RESOLVE THE PROBLEM. TO ME IT SOUNDS LIKE A RECALL IS NEEDED TO ADDRESS THIS ISSUE. IT SHOULDN'T TAKE A SEVERE ACCIDENT OR DEATH TO REMEDY THIS SITUATION. IT SOUNDS LIKE FORD IS TRYING TO AVOID ISSUING A RECALL ON THIS FROM THE COMPLAINTS THAT I HAVE REVIEWED. IF THE 2005 FORD EXPEDITION IS THE ONLY MODEL YEAR AFFECTED, THEN THERE IS SOMETHING THAT WAS PROGRAMMED OR INSTALLED INCORRECTLY ON THE FORD EXPEDITIONS FROM THAT MODEL YEAR. AN INVESTIGATION NEEDS TO BE INITIATED BEFORE THE FATAL RESULTS THAT TOYOTA HAS HAD RECENTLY BECOME A PART OF FORDS FUTURE, AND ALL BECAUSE THEY WANT TO BE IN DENIAL OF A PROBLEM WHICH SHOULD INITIATE A RECALL TO FIX. *TR
NHTSA ODI #10324024
Mileage unknown · Mar 14, 2010
SuspensionCrash
I HAVE OWNED TWO FORD EXPEDITIONS, BOTH OF WHICH WERE WRECKED WHEN IT RAINED. MY CONCERN IS THAT THE VEHICLE BECOMES VERY LOOSE IN THE REAR WHEN IT RAINS AND THAT IS THE PROBLEM THAT HAS LEAD TO ME HAVING MY ACCIDENTS. *TR
NHTSA ODI #10319504
99,000 miles · Mar 10, 2010
Engine And Engine CoolingVehicle Speed Control
2005 FORD EXPEDITION WITH 90,000 MILES ON IT, DRIVEN IN NORMAL VEHICLE STALLS WHILE DRIVING UNDER NORMAL CONDITIONS, AND THE "CHECK ELECTRONIC THROTTLE CONTROL" MESSAGE COMES ON INFOR SCREEN, THEN ENGINE LIGHT COMES ON. ALMOST RAN INTO DITCH ALONG SIDE OF ROAD LAST TIME WHEN ENGINE STALLED, AS POWER STEERING AND BRAKES SHUT DO…
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2005 FORD EXPEDITION WITH 90,000 MILES ON IT, DRIVEN IN NORMAL VEHICLE STALLS WHILE DRIVING UNDER NORMAL CONDITIONS, AND THE "CHECK ELECTRONIC THROTTLE CONTROL" MESSAGE COMES ON INFOR SCREEN, THEN ENGINE LIGHT COMES ON. ALMOST RAN INTO DITCH ALONG SIDE OF ROAD LAST TIME WHEN ENGINE STALLED, AS POWER STEERING AND BRAKES SHUT DOWN AS WELL. *TR
NHTSA ODI #10318468
70,000 miles · Mar 3, 2010
Fuel System, GasolineTiresVehicle Speed Control
I HAVE A 2005 FORD EXPEDITION LIMITED. MY COMPLAINT IS THE THROTTLE BODY FAILURE. WHEN DRIVING DOWN THE ROAD, THE ENGINE WILL SHUT DOWN AND YOU LOOSE ALL POWER TO THE VEHICLE. I HAVE HAD THIS HAPPEN AT SPEEDS OF 55+ MPH AS WELL AS SPEEDS OF APPROX LESS THAN 10 MPH, SUCH AS WHILE IN A PARKING LOT. THIS PROBLEM STARTED IN THE …
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I HAVE A 2005 FORD EXPEDITION LIMITED. MY COMPLAINT IS THE THROTTLE BODY FAILURE. WHEN DRIVING DOWN THE ROAD, THE ENGINE WILL SHUT DOWN AND YOU LOOSE ALL POWER TO THE VEHICLE. I HAVE HAD THIS HAPPEN AT SPEEDS OF 55+ MPH AS WELL AS SPEEDS OF APPROX LESS THAN 10 MPH, SUCH AS WHILE IN A PARKING LOT. THIS PROBLEM STARTED IN THE SUMMER OF 2009, AND HAS HAPPENED EVERY MONTH SINCE, SOMETIMES SEVERAL TIMES DURING THE MONTH. WE TOOK THE VEHICLE TO HAVE IT TESTED AND WERE TOLD IT WAS A TPS SENSOR. THAT HAS BEEN REPLACED ($75.00) BUT THE PROBLEM IS STILL HAPPENING. I HAVE DONE SOME RESEARCH ON THIS AND IT IS AN ONGOING PROBLEM WITH THE 2005 EXPEDITIONS. I PERSONALLY KNOW OF 2 OTHER PEOPLE THAT HAVE HAD THE SAME PROBLEM AND HAVE HAD TO HAVE THE ENTIRE THROTTLE BODY REPLACED, ONE OF WHICH HAS HAD IT REPLACED TWICE NOW. THIS IS A HUGE CONCERN SINCE YOU DO LOOSE ALL POWER AND HAVE TO TRY TO COAST TO THE SIDE OF THE ROAD, WHILE TRYING TO AVOID BEING HIT BY OTHER VEHICLES ON THE ROAD. MY CONCERN IS THAT WHEN THIS HAPPENS, THE RESULT WILL BE A ACCIDENT WHILE TRYING TO GET THE VEHICLE TO THE SIDE OF THE ROAD. THE REPAIR COST FOR JUST THE PARTS IS $600.00, BUT THIS DOES NOT INCLUDE THE LABOR. FORD NEEDS TO RECALL THIS PART BEFORE SOMEONE DOES DIE OR IS SERIOUSLY INJURED, AS IT IS A HUGE SAFETY CONCERN. FORD AND THEIR DEALERS ARE AWARE OF THE PROBLEM, YET THE ONLY RESOLUTION IS TO HAVE THE CONSUMER PAY FOR THE REPAIRS. I AM AFRAID TO DRIVE MY VEHICLE NOW BECAUSE OF THIS PROBLEM. I DO NOT HAVE THE OLD TPS SENSOR, BUT THE VEHICLE IS STILL DOING THIS AND DO STILL HAVE THE THROTTLE BODY THAT IS BAD ON THE VEHICLE FOR INSPECTION. WHEN THIS HAPPENS, THE INFORMATION CENTER IN THE DASH TELLS YOU TO "CHECK ELECTRONIC THROTTLE CABLE". *TR
NHTSA ODI #10316047
61,000 miles · Mar 1, 2010
Fuel System, Other
INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6) 2005 FORD EXPEDITION [XXX] ENGINE SHUTS DOWN WHILE TRAVELING 50 MPH, FAILSAFE MODE INDICATOR LIGHT COMES ON. THIS HAS HAPPENED TWICE IN THE LAST MONTH. IT IS A HUGE LIFE SAFETY ISSUE WHEN YOU THINK YOU HAVE CONTROL OF THE VEHICLE AND Y…
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INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6) 2005 FORD EXPEDITION [XXX] ENGINE SHUTS DOWN WHILE TRAVELING 50 MPH, FAILSAFE MODE INDICATOR LIGHT COMES ON. THIS HAS HAPPENED TWICE IN THE LAST MONTH. IT IS A HUGE LIFE SAFETY ISSUE WHEN YOU THINK YOU HAVE CONTROL OF THE VEHICLE AND YOU ACTUALLY DO NOT. I HAVE 4 CHILDREN I PUT INTO THIS VEHICLE AND I FEAR OUR SAFETY. I HAVE BEEN TOLD TODAY BY FORD THAT THE THROTTLE BODY IS FAULTY AND NEEDS TO BE REPLACED. THIS IS A PART THAT SHOULD NEVER HAVE TO BE REPLACED! CLEANED MAYBE BUT NEVER REPLACED. I HAVE 61, 000 MILES ON THE VEHICLE AND THIS PART SHOULD NOT BE BAD. I WILL BE REPLACING IT THIS WEEK, BUT I FEEL THAT FORD DOES NOT WANT TO ADDRESS THIS MATTER AS I SPOKE TO THE SERVICE MANAGER,[XXX]AT AL PACKER FORD WEST 561-790-1100 AND ALSO FORD CORPORATE OFFICE AT 800-241-3673 AND ALL THEY SAID THEY WOULD DO IS DOCUMENT THE PROBLEM. HOW MANY PEOPLE WILL CRASH OR DIE BEFORE SAFETY IS TAKEN SERIOUSLY? WHY DO DEALERSHIPS NOT TAKE RESPONSIBILITY FOR FAULTY PARTS. THIS IS A VERY FRIGHTENING EXPERIENCE FOR BOTH MYSELF AND MY CHILDREN AND IT HAS BEEN DOCUMENTED AND VERBALLY EXPRESSED TO SEVERAL PEOPLE NOW. I WOULD LIKE TO SEE ACTION TAKEN BEFORE SOMEONE DIES. *TR
NHTSA ODI #10315082
72,200 miles · Feb 26, 2010
Power Train
FORD EXPEDITION 2005 TRANSMISSION FAIL, SUV HAS BEEN DRIVEN IN NORMAL WAY, WITH GOOD MAINTENANCE. TOO NEW TO FAIL. MY WARRANTY EXPIRED AND I KNOW MANY OWNERS HAVE THE SAME PROBLEM. SUDDENLY O/D DASH LED BLINKING AND AFTER 10 MINUTES ONLY REVERSE GEAR WORKS WELL, NOW I NEED TO PAY 2500.00 DLLS FOR REPAIR ON VEHICLE NOT PAID OFF…
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FORD EXPEDITION 2005 TRANSMISSION FAIL, SUV HAS BEEN DRIVEN IN NORMAL WAY, WITH GOOD MAINTENANCE. TOO NEW TO FAIL. MY WARRANTY EXPIRED AND I KNOW MANY OWNERS HAVE THE SAME PROBLEM. SUDDENLY O/D DASH LED BLINKING AND AFTER 10 MINUTES ONLY REVERSE GEAR WORKS WELL, NOW I NEED TO PAY 2500.00 DLLS FOR REPAIR ON VEHICLE NOT PAID OFF YET. *TR
NHTSA ODI #10314475
78,000 miles · Feb 24, 2010
Fuel System, GasolineVehicle Speed Control
2005 FORD EXPEDITION 78,000 MILES. IN THE LAST FEW MONTHS THE CAR AT TIMES HAS FELT AS THOUGH THERE IS LITTLE TO NO ACCELERATION, ALMOST LIKE THE CAR IS IN NEUTRAL. TODAY MY CAR STALLED AND I WAS ABLE TO DRIFT TO THE SIDE OF THE ROAD. THE "CHECK ELECTRONIC THROTTLE" LIGHT CAME ON. THE CAR IS AT THE DEALER NOW, WITH A $600+ R…
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2005 FORD EXPEDITION 78,000 MILES. IN THE LAST FEW MONTHS THE CAR AT TIMES HAS FELT AS THOUGH THERE IS LITTLE TO NO ACCELERATION, ALMOST LIKE THE CAR IS IN NEUTRAL. TODAY MY CAR STALLED AND I WAS ABLE TO DRIFT TO THE SIDE OF THE ROAD. THE "CHECK ELECTRONIC THROTTLE" LIGHT CAME ON. THE CAR IS AT THE DEALER NOW, WITH A $600+ REPAIR BILL. SEEMS THERE SHOULD BE A CHECK FOR SUCH SYSTEMS. WHAT WOULD HAVE HAPPENED HAD I BEEN ON A BUSIER STREET OR FREEWAY. *TR
NHTSA ODI #10313929
60,000 miles · Feb 24, 2010
Vehicle Speed Control
3RD INCIDENT OF THIS ISSUE WITH THIS VEHICLE AND MULTIPLE COMPLAINTS ONLINE. VEHICLE RUNS FINE AND THE WRENCH LIGHT WILL COME ON WITH A MESSAGE "ELECTRONIC THROTTLE CONTROL" THE VEHICLE REMAINS ON BUT THROTTLE DOES NOT OPERATE. ONE OF THE INCIDENTS HAPPENED IN AN INTERSECTION AND UNDER SIMILAR CIRCUMSTANCES WOULD HAVE RESULTED…
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3RD INCIDENT OF THIS ISSUE WITH THIS VEHICLE AND MULTIPLE COMPLAINTS ONLINE. VEHICLE RUNS FINE AND THE WRENCH LIGHT WILL COME ON WITH A MESSAGE "ELECTRONIC THROTTLE CONTROL" THE VEHICLE REMAINS ON BUT THROTTLE DOES NOT OPERATE. ONE OF THE INCIDENTS HAPPENED IN AN INTERSECTION AND UNDER SIMILAR CIRCUMSTANCES WOULD HAVE RESULTED IN A CRASH. IF THE VEHICLE IS TURNED OFF AND RESTARTED IT WORKS FINE UNTIL NEXT INCIDENT. THIS IS VERY DANGEROUS AND I AM VERY SURPRISED THAT THIS HAS NOT BEEN RECALLED WITH THE NUMEROUS COMPLAINTS OF THIS ISSUE DOCUMENTED ON THE INTERNET. *TR
NHTSA ODI #10313735
80,000 miles · Feb 17, 2010
Fuel System, Gasoline
DRIVING NORMALLY ON THE HIGHWAY, VEHICLE STALLS AT REGULAR SPEED, LOSS OF ALL POWER, COAST TO A STOP ON THE SHOULDER OF THE HIGHWAY. *TR
NHTSA ODI #10311304
64,085 miles · Feb 14, 2010
Electrical System
MY 2005 FORD EXPEDITION SUDDENLY LOST ALL POWER WHILE DRIVING IN ROSEVILLE, CA ON SATURDAY FEBRUARY 13TH 2010. MY FAMILY OF FOUR WAS IN THE CAR, AND LUCKILY, WE AVOIDED AN ACCIDENT. A "ENGINE FAIL SAFE MODE" LIGHT CAME ON, AND I HAD TO PULL ON THE SIDE OF THE ROAD. I RESTARTED MY VEHICLE WITH NO PROBLEMS. *TR
NHTSA ODI #10310262
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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