NHTSA owner reports · September 18, 2026 snapshot.
What owners actually said
315 reports100,150 miles · Dec 4, 2009
Electronic Stability Control (esc)
I WAS DRIVING ON CENTRAL EXPRESSWAY THIS MORNING (12/4) AND MY 2005 FORD EXPEDITION GAVE ME AN "ELECTRONIC THROTTLE" ERROR MESSAGE AND SHUT DOWN. I WAS DRIVING ~50 MILES AN HOUR IN THE MIDDLE LANES. EXTREMELY UNSAFE AND SEE ON THE INTERNET THAT THERE HAVE BEEN SEVERAL 2005 EXPEDITIONS WHO HAVE EXPERIENCED THE SAME SITUATION. …
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I WAS DRIVING ON CENTRAL EXPRESSWAY THIS MORNING (12/4) AND MY 2005 FORD EXPEDITION GAVE ME AN "ELECTRONIC THROTTLE" ERROR MESSAGE AND SHUT DOWN. I WAS DRIVING ~50 MILES AN HOUR IN THE MIDDLE LANES. EXTREMELY UNSAFE AND SEE ON THE INTERNET THAT THERE HAVE BEEN SEVERAL 2005 EXPEDITIONS WHO HAVE EXPERIENCED THE SAME SITUATION. I THOUGHT THE PART WOULD HAVE BEEN RECALLED OR THAT FORD WOULD HAVE FIXED THIS PART AS I BOUGH THIS VEHICLE USED FROM THEIR DEALERSHIP. VERY DISAPPOINTING. *TR
NHTSA ODI #10294517
59,269 miles · Nov 30, 2009
Service Brakes, HydraulicCrashInjury
I HAD JUST PICKED UP MY SON FROM HIS SCHOOL AND MADE A LEFT TURN AT THE STOP SIGN TO GO TO THE MAIN ROAD TO PICK MY DAUGHTER FROM HER SCHOOL WHEN THE BRAKES FAILED IN MY TRUCK. THE RED WAS AHEAD,CARS WERE LINED,KIDS WERE CROSSING THE ROAD,AND I HAD TO SOMETHING REALLY FAST. I DROVE IN TO A DRIVEWAY IN MY RIGHT WHICH WAS A PARKIN…
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I HAD JUST PICKED UP MY SON FROM HIS SCHOOL AND MADE A LEFT TURN AT THE STOP SIGN TO GO TO THE MAIN ROAD TO PICK MY DAUGHTER FROM HER SCHOOL WHEN THE BRAKES FAILED IN MY TRUCK. THE RED WAS AHEAD,CARS WERE LINED,KIDS WERE CROSSING THE ROAD,AND I HAD TO SOMETHING REALLY FAST. I DROVE IN TO A DRIVEWAY IN MY RIGHT WHICH WAS A PARKING FOR A HOSPITAL. I KEPT TRYING TO PUSH THE BRAKE PEDAL TO STOP THE CAR,BUT THE WOULDN'T STOP. IT WENT OVER THE CURB AND HIT A TREE. I CALLED THE POLICE, THEN MY INSURANCE,CAR WAS TOWED TO THE BODY SHOP. THE FORD STORE DID THE DIAGNOSTICS ON THE BRAKE AND TOLD MY INSURANCE COMPANY THAT THE BRAKE BOOSTER HAD FAILED.MY INSURANCE COMPANY GOT THE WORK STARTED FOR THE BODY DAMAGE. I CALLED THE FORD STORE SEVERAL TIMES ASKING FOR A COPY OF THE DIAGNOSTIC AND THE PERSON IN CHARGE WOULD NOT RETURN MY CALL OR GIVE ME A COPY.THREE WEEKS LATER WHEN BODY STARTED THEY SENT A REPORT TO THE BODY SHOP THAT THE CAUSE OF THE ACCIDENT, WAS UNDETERMINED SENT THIS REPORT AFTER HE SPOKE TO THE OFFICE OF THE GENERAL COUNSEL OF FORD. THE ACCIDENT OCCURRED AT 3:15 ON SEPT.17TH AND MY CAR WENT THROUGH A 60,000 MILE CHECK UP ON SEPT.16TH. AT THE FORD STORE. *TR
NHTSA ODI #10294090
53,000 miles · Nov 16, 2009
Vehicle Speed Control
DRIVING 2005 FORD EXPEDITION PASSED THROUGH INTERSECTION DRIVING 45 MPH AND ALL OF A SUDDEN CAR LIGHT TURNED ON AND READ ELECTRONIC THROTTLE CONTROL FAILURE AND CAR IMMEDIATELY COULD NOT DRIVE OVER 5 MPH. I TURNED AND GOT OFF THE MAIN ROAD, SCARED THAT I WAS GOING TO GET HIT BY ANOTHER CAR. WAS ABLE TO TURN CAR BACK ON AFTER L…
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DRIVING 2005 FORD EXPEDITION PASSED THROUGH INTERSECTION DRIVING 45 MPH AND ALL OF A SUDDEN CAR LIGHT TURNED ON AND READ ELECTRONIC THROTTLE CONTROL FAILURE AND CAR IMMEDIATELY COULD NOT DRIVE OVER 5 MPH. I TURNED AND GOT OFF THE MAIN ROAD, SCARED THAT I WAS GOING TO GET HIT BY ANOTHER CAR. WAS ABLE TO TURN CAR BACK ON AFTER LEAVING THE CAR THEIR FOR A FEW HOURS, TOLD THAT I NEEDED TO REPLACE THE THROTTLE BODY AND I HAVE 53,000 AND NOT UNDER WARRENTLY. THIS IS A SAFETY CONCERN THIS COULD HAVE CAUSED A SERIOUS ACCIDENT! *TR
NHTSA ODI #10292431
127,000 miles · Nov 6, 2009
Engine And Engine CoolingFuel System, Other
2005 FORD EXPEDITION 5.4 ENGINE, MISFIRING 3&5 CYLINDER. ROUGH IDLE. CAR HAS 127,000 MILES AND SINCE WE HAVE HAD IT I HAD ISSUES WITH IT IDLING IN PARK AND ALMOST AT TIMES WANTING TO STALL. ENGINE HAS ON MORE THAN 3 OCCASIONS WHILE DRIVING 60-70 MPH ON THE HIGHWAY BECOME UN RESPONSIVE WHILE DRIVING. ENGINE WOULD RUN BUT NO ACCEL…
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2005 FORD EXPEDITION 5.4 ENGINE, MISFIRING 3&5 CYLINDER. ROUGH IDLE. CAR HAS 127,000 MILES AND SINCE WE HAVE HAD IT I HAD ISSUES WITH IT IDLING IN PARK AND ALMOST AT TIMES WANTING TO STALL. ENGINE HAS ON MORE THAN 3 OCCASIONS WHILE DRIVING 60-70 MPH ON THE HIGHWAY BECOME UN RESPONSIVE WHILE DRIVING. ENGINE WOULD RUN BUT NO ACCELERATION WHEN THE GAS PEDAL WAS PUSHED; IT WAS LIKE THE CAR WAS RUNNING IN NEUTRAL. INDICATOR LIGHT CAME ON SHOWING "ENGINE FAILURE". PULLED OFF THE ROAD AND RESTARTED CAR AND THEN IT RAN FINE AGAIN. FORD SVC DEPT. COULD NOT REPLICATE THE SITUATION WHEN I TOOK IT TO THEM, SO IT WAS NEVER REPAIRED. (CLEARLY THERE IS A FAULTY PROBLEM) CURRENTLY CAR IS IN THE SHOP REPLACING ALL 8 SPARK PLUGS, COILS AND BOOTS. MECHANIC INDICATED A LOT OF CARBON BUILDUP IN THROTTLE BODY. (SEEMS TO ME POSSIBLY SOME OTHER FAULTY COMPONENT COULD BE WHY I'M HAVING TO SPEND $800 TO FULLY REPAIR MY CAR). *TR
NHTSA ODI #10291248
64,721 miles · Oct 30, 2009
Engine And Engine CoolingFuel System, Other
2005 FORD EXPEDITION DISPLAYED "ELECTRONIC THROTTLE CONTROL FAILURE" MESSAGE AND ENGINE ABRUPTLY QUIT AT HIGH SPEED IN TRAFFIC ON A CURVED ROAD RESULTING IN A SIMULTANEOUS LOSS OF POWER STEERING AND POWER BRAKES. THIS APPEAR TO BE A COMMON PROBLEM FOR WHICH THERE HAS BEEN NO SAFETY RECALL. A FAILURE LIKE THIS WITH NO MECHANICA…
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2005 FORD EXPEDITION DISPLAYED "ELECTRONIC THROTTLE CONTROL FAILURE" MESSAGE AND ENGINE ABRUPTLY QUIT AT HIGH SPEED IN TRAFFIC ON A CURVED ROAD RESULTING IN A SIMULTANEOUS LOSS OF POWER STEERING AND POWER BRAKES. THIS APPEAR TO BE A COMMON PROBLEM FOR WHICH THERE HAS BEEN NO SAFETY RECALL. A FAILURE LIKE THIS WITH NO MECHANICAL BACKUP FOR ENGINE THROTTLE CONTROL IS A SERIOUS SAFETY ISSUE. *TR
NHTSA ODI #10290423
45,000 miles · Oct 23, 2009
Vehicle Speed Control
TL* THE CONTACT OWNS A 2005 FORD EXPEDITION. WHILE DRIVING 25 MPH THE CHECK ELECTRONIC THROTTLE CONTROL WARNING LIGHT ILLUMINATED ON THE INSTRUMENT CONTROL PANEL, AND THEN THE VEHICLE STALLED. HE WAS ABLE TO SAFELY RESTART THE VEHICLE TO RESUME NORMAL VEHICLE OPERATION. THE DEALER WAS NOTIFIED, AND A TECHNICIAN STATED THAT THE…
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TL* THE CONTACT OWNS A 2005 FORD EXPEDITION. WHILE DRIVING 25 MPH THE CHECK ELECTRONIC THROTTLE CONTROL WARNING LIGHT ILLUMINATED ON THE INSTRUMENT CONTROL PANEL, AND THEN THE VEHICLE STALLED. HE WAS ABLE TO SAFELY RESTART THE VEHICLE TO RESUME NORMAL VEHICLE OPERATION. THE DEALER WAS NOTIFIED, AND A TECHNICIAN STATED THAT THEY WERE AWARE OF THE FAILURE, BUT BECAUSE THEY WERE NO RECALLS THEY WOULD NOT PROVIDE ANY ASSISTANCE. THE VEHICLE WILL BE REPAIRED. THE FAILURE AND CURRENT MILEAGES WERE 45000.
NHTSA ODI #10289630
91,000 miles · Oct 9, 2009
Engine And Engine Cooling
2005 FORD EXPEDITION - ENGINE DEFAULTS TO "LIMP HOME" MODE WHILE IN TRAFFIC. HAS OCCURRED TWICE SO FAR BUT HAVE BEEN ABLE TO NEGOTIATE GETTING OFF THE ROAD. VEHICLE HAS RESTARTED AFTER SITTING FEW MINUTES. *TR
NHTSA ODI #10286950
51,195 miles · Oct 6, 2009
Power Train
TL*THE CONTACT OWNS A 2005 FORD EXPEDITION. WHEN HE ATTEMPTED TO DRIVE THE FAIL SAFE MODE WARNING LIGHT ILLUMINATED ON THE INSTRUMENT CONTROL PANEL, AND THEN THE VEHICLE STALLED. THE THROTTLE ALSO DISENGAGED, WHICH CAUSED THE VEHICLE TO DRIVE IN NEUTRAL GEAR. HE USUALLY HAS TO RESTART THE VEHICLE TO RESUME NORMAL OPERATION. NO …
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TL*THE CONTACT OWNS A 2005 FORD EXPEDITION. WHEN HE ATTEMPTED TO DRIVE THE FAIL SAFE MODE WARNING LIGHT ILLUMINATED ON THE INSTRUMENT CONTROL PANEL, AND THEN THE VEHICLE STALLED. THE THROTTLE ALSO DISENGAGED, WHICH CAUSED THE VEHICLE TO DRIVE IN NEUTRAL GEAR. HE USUALLY HAS TO RESTART THE VEHICLE TO RESUME NORMAL OPERATION. NO REPAIRS WERE MADE. THE FAILURE MILEAGE WAS 51,195. THE CURRENT MILEAGE WAS 61,000.
NHTSA ODI #10286400
70,000 miles · Oct 1, 2009
Engine And Engine Cooling
WHILE TRAVELING AT AROUND 50-60 MPH, THE VEHICLE LOST POWER AND I PULLED OVER INTO A PARKING LOT. THE DASH EXHIBITED A SYMBOL IMPLYING THE "ELECTRONIC THROTTLE" WAS MALFUNCTIONING. THIS IS QUITE DANGEROUS BECAUSE IT OCCURS WHILE DRIVING DOWN THE STREET WITH NO PRIOR WARNING. DO NOT KNOW YET HOW MUCH REPAIR WILL BE AS IT OCCU…
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WHILE TRAVELING AT AROUND 50-60 MPH, THE VEHICLE LOST POWER AND I PULLED OVER INTO A PARKING LOT. THE DASH EXHIBITED A SYMBOL IMPLYING THE "ELECTRONIC THROTTLE" WAS MALFUNCTIONING. THIS IS QUITE DANGEROUS BECAUSE IT OCCURS WHILE DRIVING DOWN THE STREET WITH NO PRIOR WARNING. DO NOT KNOW YET HOW MUCH REPAIR WILL BE AS IT OCCURRED TODAY. NOTICED ON WEBSITE COMMENTS SECTION THAT THIS HAPPENS FREQUENTLY WITH THE 2005 FORD EXPEDITION. WANT TO KNOW WHAT FORD IS DOING ABOUT THIS. *TR
NHTSA ODI #10285932
36,000 miles · Oct 1, 2009
Engine And Engine Cooling
2005 EXPEDITION HAS SEVERE ENGINE TICKING PROBLEM (SOUNDS LIKE A DIESEL) ORIGINAL COMPLAINT WAS BEFORE WARRANTY EXPIRED TOLD BY DEALER THAT IT WAS THE "3 VALVE MOTOR NOISE". WHEN IT GOT WORSE AT AROUND 37K MILES (1K) OUT OF WARRANTY DEALER THEN TELLS ME THAT THERE HAS BEEN A TSB ISSUED (TSB 06-4-7 ORIGINAL VERSION WAS ACTUALLY I…
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2005 EXPEDITION HAS SEVERE ENGINE TICKING PROBLEM (SOUNDS LIKE A DIESEL) ORIGINAL COMPLAINT WAS BEFORE WARRANTY EXPIRED TOLD BY DEALER THAT IT WAS THE "3 VALVE MOTOR NOISE". WHEN IT GOT WORSE AT AROUND 37K MILES (1K) OUT OF WARRANTY DEALER THEN TELLS ME THAT THERE HAS BEEN A TSB ISSUED (TSB 06-4-7 ORIGINAL VERSION WAS ACTUALLY ISSUED SHORTLY AFTER THE TRUCK WAS BUILT) IT IS THE CAM PHASERS AND VALVE LASH ADJUSTERS AND IT WILL BE $3000 TO REPAIR AND NOW NOT COVERED UNDER WARRANTY. I HAVE REPEATEDLY WORKED WITH THE DEALER AND FORD CUSTOMER CARE TO RESOLVE ISSUE THE LAST PERSON AT CUSTOMER CARE TOLD ME "ITS YOUR PROBLEM" JUST BEFORE HANGING UP ON ME. THIS AFTER A SIMILAR PULLING TEETH EPISODE TO GET THEM TO FIX THE KNOWN CORROSION PROBLEM THAT THEY HAD AND DENIED BEFORE I FOUND A TSB ABOUT THAT TOO, I NOW HAVE ANOTHER LARGE RUST SPOT ON MY BACK DOOR THAT THE WILL NOT FIX EITHER. ALL OF THIS AFTER I PAID $4000 TO GET RID OF THE LINCOLN LS THAT I OWNED THAT THEY COULD NOT KEEP RUNNING AFTER DUMPING THOUSANDS OF DOLLARS INTO A COP PROBLEM THAT WAS EVENTUALLY COVERED UNDER A CUSTOMER CARE PROGRAM. I SURE DID NOT GET ANY MONEY BACK ON THAT. SOMEONE HAS TO WAKE SOMEONE OVER AT FORD UP AND GET THEM TO FIX THIS GARBAGE THEY HAVE BEEN TURNING OUT.. *TR
NHTSA ODI #10285892
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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