← New search

2005 Ford Expedition

Owner reports · Recalls · Investigations

More warning signs than most Expedition years

Owner complaints for the 2005 Ford Expedition are substantially higher than the model-year median of 155.

About this comparison →

When problems were reported

Mileage at the reported incident

289 reports with mileage · 26 unknown

NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.

What to inspect

Issues worth paying extra attention to based on owner reports.

  • Electrical System. Review the 76 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Vehicle Speed Control. Review the 66 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Engine. Review the 57 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

20 crash reports6 fire reports10 injury reports

What owners actually said

315 reports
62,572 miles · Feb 12, 2010
Electronic Stability Control (esc)Vehicle Speed Control

2005 FORD EXPEDITION. WHILE DRIVING ON THE HWY THE "CHECK ELECTRONIC THROTTLE CONTROL" LIGHT CAME ON AND PUT THE VEHICLE IN "LIMP MODE" I HAD NO ACCELERATOR PEDAL CONTROL. DECEMBER 22, 2008. TAKEN TO DEALER, NO PROBLEM FOUND. CODE WAS " P2104". SAME THING HAPPENED AGAIN DECEMBER 20, 2009. TAKEN TO DEALER NO PROBLEM OR CODE FOUND…

Read full complaint

2005 FORD EXPEDITION. WHILE DRIVING ON THE HWY THE "CHECK ELECTRONIC THROTTLE CONTROL" LIGHT CAME ON AND PUT THE VEHICLE IN "LIMP MODE" I HAD NO ACCELERATOR PEDAL CONTROL. DECEMBER 22, 2008. TAKEN TO DEALER, NO PROBLEM FOUND. CODE WAS " P2104". SAME THING HAPPENED AGAIN DECEMBER 20, 2009. TAKEN TO DEALER NO PROBLEM OR CODE FOUND. WHEN THIS HAPPENS ,YOU HAVE NO POWER. YOU HAVE TO COAST TO THE SIDE OF THE ROAD AND CALL FOR HELP. *TR

NHTSA ODI #10308927

75,200 miles · Feb 8, 2010
Engine And Engine Cooling

UNTIL TODAY I HAVE BEEN A LOYAL FORD VEHICLE OWNER. MY WIFE WAS TAKING OUR THREE CHILDREN TO SCHOOL THIS MORNING AND AS SHE WAS MERGING ONTO THE HIGHWAY SHE WAS ALERTED TO AN UNFAMILIAR CODE AND ALARM IN THE VEHICLE. BEFORE SHE COULD LOOK AT THE DASHBOARD THE VEHICLE LOST ALL POWER AND WOULD NOT ACCELERATE IN THE ACCELERATION LA…

Read full complaint

UNTIL TODAY I HAVE BEEN A LOYAL FORD VEHICLE OWNER. MY WIFE WAS TAKING OUR THREE CHILDREN TO SCHOOL THIS MORNING AND AS SHE WAS MERGING ONTO THE HIGHWAY SHE WAS ALERTED TO AN UNFAMILIAR CODE AND ALARM IN THE VEHICLE. BEFORE SHE COULD LOOK AT THE DASHBOARD THE VEHICLE LOST ALL POWER AND WOULD NOT ACCELERATE IN THE ACCELERATION LANE, THE BRAKING AND STEERING BECAME MINIMAL AND SHE WAS LEFT WITH A LITTLE MORE THAN A DISABLED VEHICLE ON THE HIGHWAY. WITH HEAVY RUSH HOUR TRAFFIC RAPIDLY APPROACHING HER AND UNSURE WHETHER THEY COULD STOP SHE HAD TO FORCE THE VEHICLE TO THE EDGE OF THE GUARDRAIL. THE VEHICLE WHEN TURNED OFF AND RESTARTED APPEARED NORMAL. I THEN CHECKED PRIOR COMPLAINTS ON THIS WEB SITE AND OTHERS AND AM APPALLED OF THE LACK OF ACTION BY FORD MOTOR COMPANY AND OTHERS FOR NOT LOOKING INTO THIS ISSUE. THE LIVES OF THREE SMALL CHILDREN AND WHOEVER ELSE MAY HAVE BEEN INVOLVED IN THIS POTENTIAL COLLISION DESERVE TO HAVE FORD ACKNOWLEDGE THIS PROBLEM. I PURCHASED THE EXTENDED WARRANTY FROM FORD AND WHEN I TALKED ON THE PHONE WITH THEM THIS MORNING, THEY TOLD ME THAT THEY WOULD JUST "KEEP AN EYE ON IT". WHEN THEY LOOKED ON THE COMPUTER TO INFORM ME MY WARRANTY HAD EXPIRED 200 MILES AGO THEY CHANGED THEIR MIND AND TOLD ME TO BRING IT IN. PLEASE, PLEASE LOOK INTO THIS OBVIOUS DEFECT. I AM A POLICE OFFICER AND SEE TOO MANY FATALITIES DUE TO OTHER CONTRIBUTING FACTORS. I WOULD NOT WANT TO SEE ONE BECAUSE OF AN ORGANIZATION FAILING TO TAKE ACCOUNTABILITY.

NHTSA ODI #10307367

47,000 miles · Feb 1, 2010
Electrical System

SEVERAL TIMES WHILE DRIVING MY FORD 2005 EXPEDITION THE CAR STOPS RESPONDING TO THE THROTTLE AND LOSSES ALL POWER CAUSING AN UNSAFE CONDITION IN TRAFFIC. 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 HAV…

Read full complaint

SEVERAL TIMES WHILE DRIVING MY FORD 2005 EXPEDITION THE CAR STOPS RESPONDING TO THE THROTTLE AND LOSSES ALL POWER CAUSING AN UNSAFE CONDITION IN TRAFFIC. 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 #10303658

97,815 miles · Jan 29, 2010
Fuel System, Gasoline

I HAVE A 2005 EXPEDITION AND IT JUST CUT OFF! I WAS DRIVING ABOUT 40 MILES PER HOUR AND IT JUST CUT OFF WHILE I WAS PRESSING ON THE GAS. I HAD TO COAST OFF THE SIDE OF THE ROAD. I ALMOST GOT IN AN ACCIDENT! A WARNING ALERT SAID CHECK ELECTRONIC THROTTLE AND I COULD NOT MOVE IT AND JUST STOP AND DIED. I WAITED ABOUT 5 MINUT…

Read full complaint

I HAVE A 2005 EXPEDITION AND IT JUST CUT OFF! I WAS DRIVING ABOUT 40 MILES PER HOUR AND IT JUST CUT OFF WHILE I WAS PRESSING ON THE GAS. I HAD TO COAST OFF THE SIDE OF THE ROAD. I ALMOST GOT IN AN ACCIDENT! A WARNING ALERT SAID CHECK ELECTRONIC THROTTLE AND I COULD NOT MOVE IT AND JUST STOP AND DIED. I WAITED ABOUT 5 MINUTES AND TRIED TO START MY CAR AGAIN AND IT STARTED. THE ENGINE LIGHT WAS ON AND TOOK IT TO AUTOZONE AND THE DIAGNOSTIC SAYS THAT THE THROTTLE IS STUCK. THIS HAPPENED TO ME LAST YEAR AROUND ABOUT THE SAME TIME AND JUST WENT AWAY. THE YEAR BEFORE I BROUGHT THE CAR FROM THE DEALERSHIP AND IT DID THIS TO ME 3 DAYS AFTER I BOUGHT IT. I TOOK IT BACK TO GET IT REPAIRED AND THEY FIXED IT NO CHARGE. NOW THEY ARE TRYING TO CHARGE ME. IT COST 700 DOLLARS EVERYTIME THIS PART GOES OUT. WHY SHOULD I HAVE TO KEEP GETTING THIS REPAIRED? THERE SHOULD BE A RECALL ON THIS VEHICLE (ELECTRIC THROTTLE). THERE ARE PLENTY OF COMPLAINTS ABOUT THIS PART. PLEASE INVESTIGATE AND SEE FOR YOURSELVES. IF YOU DO RESEARCH ON HOW MAY TIME PEOPLE HAVE TO GO FOR REPEAT REPAIR, I AM SURE IT WOULD BE OFF THE CHARTS. IT HAS A POOR DESIGN. IT COULD POTENTIALLY GET SOME KILLED, IF NOT ALREADY. I WAS IN THE CAR WITH MY CHILDREN AND I WAS SCARED! *TR

NHTSA ODI #10303199

57,368 miles · Jan 21, 2010
Electrical System

WHILE TRAVELING AT APPROXIMATELY 60 MPH IN MORNING RUSH HOUR ON A MAJOR HIGHWAY A MESSAGE APPEARED ON THE DISPLAY BOARD STATING CHECK ELECTRONIC THROTTLE SENSOR VEHICLE THEN IMMEDIATELY DIED AND I WAS UNABLE TO ACCELERATE. I WAS ABLE TO COAST TO THE SHOULDER ATTEMPTING TO AVOID ANY COLLISIONS. ONCE I CAME TO A STOP I PLACED THE…

Read full complaint

WHILE TRAVELING AT APPROXIMATELY 60 MPH IN MORNING RUSH HOUR ON A MAJOR HIGHWAY A MESSAGE APPEARED ON THE DISPLAY BOARD STATING CHECK ELECTRONIC THROTTLE SENSOR VEHICLE THEN IMMEDIATELY DIED AND I WAS UNABLE TO ACCELERATE. I WAS ABLE TO COAST TO THE SHOULDER ATTEMPTING TO AVOID ANY COLLISIONS. ONCE I CAME TO A STOP I PLACED THE VEHICLE IN PARK AND TURNED THE IGNITION OFF. AFTER A FEW MINUTES I RESTARTED THE CAR WITHOUT ANY PROBLEMS. THE MESSAGE ON THE DISPLAY SCREEN WAS NO LONGER THERE BUT THE CHECK ENGINE WAS ON. FOR THE REMAINDER OF THE DAY I HAD NO FURTHER ISSUES. THE FOLLOWING DAY AFTER WORK IT HAPPENED AGAIN IN 5:00 TRAFFIC. ONCE RETURNING HOME I BEGAN TO DO SOME RESEARCH ON THIS ISSUE. TO MY SURPRISE I AM NOT THE ONLY ONE HAVING THIS ISSUE. THERE ARE 100'S OF POST ON LINE IN MULTIPLE PLACES INQUIRING ABOUT THIS ISSUE. MY CONCERN IS THE SAFETY OF MY FAMILY AND OTHERS THAT MAY BE ON THE HIGHWAY WHEN THIS ISSUE OCCURS. WHEN THIS OCCURS YOU ARE UNABLE TO ACCELERATE. THIS COULD CAUSE SEVERE ACCIDENTS AS WELL AS DEATHS IF THIS ISSUE IS NOT ADDRESSED. *TR

NHTSA ODI #10301677

79,800 miles · Jan 20, 2010
Vehicle Speed Control

CAR WAS RUNNING FINE THEN BEEP AND WARNING SHOWS ON DASH SOMETHING ABOUT "ELECTRONIC THROTTLE CONTROL'. THE CAR IS STILL RUNNING BUT GAS PEDAL DOESN'T WORK. I WAS STUCK AT A STREET LIGHT STOPPED UNTIL I COULD TURN OFF AND RESTART THE CAR. THIS IS THE 2ND INCIDENT WITH THIS VEHICLE. IT HAPPENED THE FIRST TIME DRIVING OVER 50 MPH …

Read full complaint

CAR WAS RUNNING FINE THEN BEEP AND WARNING SHOWS ON DASH SOMETHING ABOUT "ELECTRONIC THROTTLE CONTROL'. THE CAR IS STILL RUNNING BUT GAS PEDAL DOESN'T WORK. I WAS STUCK AT A STREET LIGHT STOPPED UNTIL I COULD TURN OFF AND RESTART THE CAR. THIS IS THE 2ND INCIDENT WITH THIS VEHICLE. IT HAPPENED THE FIRST TIME DRIVING OVER 50 MPH ON A HIGHWAY AND HAD TO COAST TO THE SIDE OF THE ROAD. THERE IS APPARENTLY NOTHING THAT CAN BE FOUND WRONG AND NO WAY TO TELL IF IT IS GOING TO HAPPENED AGAIN AND WHY IT HAPPENED. I HAVE NOT DONE ANYTHING TO REPAIR SINCE I CAN NOT FIND A REASON AS TO WHY IT HAPPENED TO HAVE IT REPAIRED. *TR

NHTSA ODI #10300417

97,600 miles · Jan 4, 2010
Electrical System

WHILE DRIVING ON TWO DIFFERENT OCCASIONS A MESSAGE HAS APPEARED ON MY INSTRUMENT PANEL SAYING, "CHECK ELECTRONIC THROTTLE CONTROL." WHEN THIS HAPPENS I IMMEDIATELY LOSE MY ACCELERATION. BOTH TIMES I WAS ON A HILL AND THANK GOODNESS I DID NOT LOSE BRAKING ABILITY AS DESCRIBED BY OTHERS. WHEN YOU ARE ON A HILL IN A VEHICLE OF THIS…

Read full complaint

WHILE DRIVING ON TWO DIFFERENT OCCASIONS A MESSAGE HAS APPEARED ON MY INSTRUMENT PANEL SAYING, "CHECK ELECTRONIC THROTTLE CONTROL." WHEN THIS HAPPENS I IMMEDIATELY LOSE MY ACCELERATION. BOTH TIMES I WAS ON A HILL AND THANK GOODNESS I DID NOT LOSE BRAKING ABILITY AS DESCRIBED BY OTHERS. WHEN YOU ARE ON A HILL IN A VEHICLE OF THIS SIZE IT IS NEARLY IMPOSSIBLE TO MANEUVER TO A SAFE LOCATION. THE FIRST TIME THIS OCCURRED WAS NOVEMBER 27, 2009 AND AGAIN YESTERDAY, JANUARY 3, 2010. I AM ALMOST 6 MONTHS PREGNANT AND TRANSPORT 4 YOUNG CHILDREN TO AND FROM SCHOOL. AFTER RESEARCHING THIS PROBLEM ONLINE, I HAVE DISCOVERED THAT THIS IS A VERY COMMON PROBLEM ON THE 2005 FORD EXPEDITION. I AM VERY AFRAID THAT SOMEONE IS GOING TO BE SERIOUSLY INJURED OR KILLED BY THIS FAILURE. I HAVE READ MANY REPORTS ON HERE DATING BACK MORE THAN A YEAR AND I AM CURIOUS AS TO WHAT IT TAKES TO HAVE THIS RECALLED. HEAVEN FORBID SOMEONE LOSES THEIR LIFE. *TR

NHTSA ODI #10297955

65,000 miles · Jan 3, 2010
Fuel System, Gasoline

2005 FORD EXPEDITION EB FUEL PUMP BROKE AT 65000 MILES. AUTO BOUGHT BRAND NEW AND IN EXCELLENT CONDITION. FORD DEALER AND FORD REP CANNOT LOCATE THE REPLACEMENT PUMP.. SAID IT WILL BE LATE FEBRUARY IF I AM LUCKY. THIS IS MY MAIN MODE OF TRANSPORTATION!! *TR

NHTSA ODI #10297874

56,261 miles · Dec 30, 2009
Engine And Engine Cooling

1. THERE WERE NO EVENTS LEADING UP TO THE FAILURE. THERE IS NO WARNING THAT THIS IS GOING TO HAPPEN OR IS HAPPENING. UNDER NORMAL DRIVING CONDITIONS, MY 2005 FORD EXPEDITION SIMPLY LOST ALL POWER AND THE WORDS "ENGINE FAIL SAFE MODE" APPEARED. 2. THIS OCCURRED TWICE (OCT. 6, 2009 AND NOV. 16, 2009). I WAS ABLE TO PULL TO…

Read full complaint

1. THERE WERE NO EVENTS LEADING UP TO THE FAILURE. THERE IS NO WARNING THAT THIS IS GOING TO HAPPEN OR IS HAPPENING. UNDER NORMAL DRIVING CONDITIONS, MY 2005 FORD EXPEDITION SIMPLY LOST ALL POWER AND THE WORDS "ENGINE FAIL SAFE MODE" APPEARED. 2. THIS OCCURRED TWICE (OCT. 6, 2009 AND NOV. 16, 2009). I WAS ABLE TO PULL TO THE SIDE OF THE ROAD BOTH TIMES BUT DURING THE SECOND INCIDENT, I LOST THE POWER STEERING AS WELL AND STRUGGLED TO PULL OVER. THE CONSEQUENCES OF THIS "ENGINE FAIL SAFE MODE" IS THAT THE CAR STOPS WORKING. YOU BECOME A SITTING DUCK WHEREVER THE CAR HAS DECIDED TO GO INTO THIS MODE. YOU ARE UNABLE TO ACCELERATE -NOT FUN WHEN THIS HAPPENED ON THE FREEWAY THE FIRST TIME-AND IF YOU DO NOT LOSE YOUR POWER STEERING, YOU CAN PULL TO THE SIDE OF THE ROAD. 3. THE ELECTRONIC THROTTLE BODY WAS REPLACED FOR APPROXIMATELY $700. NOWHERE IN THE CAR MANUAL DOES IT LET YOU KNOW THAT THIS CODE COULD LEAD TO THIS REPAIR. I HAD A HARD TIME FIGURING OUT WHAT THE CODE MEANT USING THE OWNER MANUAL. THE MOST FRUSTRATING PART OF THIS FAILURE IS THAT IF THIS HAD OCCURRED WHEN I WAS TRAVELING AT 65 MPH ON THE FREEWAY, I PROBABLY WOULD NOT BE HERE TO ENTER THIS COMPLAINT. I WOULD LIKE TO PREVENT THIS FROM HAPPENING TO SOMEONE ELSE. *TR

NHTSA ODI #10297596

80,000 miles · Dec 23, 2009
Power Train

TRANSMISSION ON 2005 EXPEDITION IS SLIPPING. WHEN THE VEHICLE IS PLACED INTO DRIVE AND THE FOOT THROTTLE IS DEPRESSED THE VEHICLE HESITATES TO MOVE FORWARD, BUT THEN JERKS FORWARD. OTHER TIMES IT SEEMS LIKE IT DOESN'T WANT TO UPSHIFT WHEN DRIVING ON THE FREEWAY. I MUST ALSO STATE THAT THE PAINT ON THE TIP OF THE HOOD AND ON TH…

Read full complaint

TRANSMISSION ON 2005 EXPEDITION IS SLIPPING. WHEN THE VEHICLE IS PLACED INTO DRIVE AND THE FOOT THROTTLE IS DEPRESSED THE VEHICLE HESITATES TO MOVE FORWARD, BUT THEN JERKS FORWARD. OTHER TIMES IT SEEMS LIKE IT DOESN'T WANT TO UPSHIFT WHEN DRIVING ON THE FREEWAY. I MUST ALSO STATE THAT THE PAINT ON THE TIP OF THE HOOD AND ON THE TAILGATE ARE STARTING TO BUBBLE /BLISTER, THE VEHICLE IS ONLY 5 YEARS OLD AND THE PAINT IS CARED FOR THROUGH POLISHING AND WAXING TWICE A YEAR. *TR

NHTSA ODI #10296852

Official recalls

0

No recalls in this snapshot.

Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗

NHTSA investigations

1

PE08070 · 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