NHTSA owner reports · September 18, 2026 snapshot.
What owners actually said
315 reports45,000 miles · Sep 16, 2009
Structure
I HAVE A 2005 FORD EXPEDITION THAT HAS PAINT BUBBLING IN DIFFERENT AREAS. I DID SOME RESEARCH ON-LINE AND FOUND THAT FORD ISSUED A TECHNICAL SERVICE BULLETIN 04-25-1 IN 2004 AND ANOTHER BULLETIN 06-25-1 IN 2006 THAT EXPLAINS THAT PRIOR TO PAINTING, IRON PARTICLES CONTAMINATED THE ALUMINUM PANEL WHICH CAUSES THE PAINT BUBBLES DO…
Read full complaint
I HAVE A 2005 FORD EXPEDITION THAT HAS PAINT BUBBLING IN DIFFERENT AREAS. I DID SOME RESEARCH ON-LINE AND FOUND THAT FORD ISSUED A TECHNICAL SERVICE BULLETIN 04-25-1 IN 2004 AND ANOTHER BULLETIN 06-25-1 IN 2006 THAT EXPLAINS THAT PRIOR TO PAINTING, IRON PARTICLES CONTAMINATED THE ALUMINUM PANEL WHICH CAUSES THE PAINT BUBBLES DOWN THE ROAD. IN MY RESEARCH ON-LINE, I FOUND THAT FORD IS NOT TAKING CARE OF THEIR CUSTOMERS, BUT SOME DEALERS ARE COVERING SOME OF THE REPAIRS UNDER A "GOODWILL POLICY". I CONTACTED A LAWYER THAT SPECIALIZES IN LEMON-LAW, AND HE SUGGESTED I FILE THIS COMPLAINT. HE SAYS IF ENOUGH PEOPLE COMPLAIN, IT MAY FORCE FORD TO TAKE ACTION AND TAKE CARE OF THEIR CUSTOMERS. I DID CONTACT MY DEALERSHIP, AND THEY SAY THEY NEVER HEARD OF THIS PROBLEM. I AM PAST MY 3 YEAR WARRANTY, SO THEY SAY IT IS NOT COVERED. *TR
NHTSA ODI #10284098
102,000 miles · Sep 15, 2009
Structure
2005 FORD EXPEDITION, PAINT CRACKING AND PEELING ON THE ROOF. OF COURSE I DID NOT NOTICE IT TILL 102,000 MILES. I DID TAKE IT TO THE DEALER AND THEY BASICALLY TOLD ME THAT FORD WOULD NOT HAVE FIXED IT 100% ANYWAY. THEY DO A ONE-THIRD (FORD), ONE-THIRD (DEALER), ONE-THIRD (CUSTOMER) PAYS. I FIND THIS VERY UNACCEPTABLE. YOU BUY A …
Read full complaint
2005 FORD EXPEDITION, PAINT CRACKING AND PEELING ON THE ROOF. OF COURSE I DID NOT NOTICE IT TILL 102,000 MILES. I DID TAKE IT TO THE DEALER AND THEY BASICALLY TOLD ME THAT FORD WOULD NOT HAVE FIXED IT 100% ANYWAY. THEY DO A ONE-THIRD (FORD), ONE-THIRD (DEALER), ONE-THIRD (CUSTOMER) PAYS. I FIND THIS VERY UNACCEPTABLE. YOU BUY A $60+++ VEHICLE AND THE PAINT HOLDS NO GUARANTEE. I GUESS I'M LUCKIER THAN THE OTHER GUY THOUGH, YOU REALLY DON'T NOTICE THE ROOF. THE DEALER SAID IT WOULD BE ABOUT A $1500 REPAINT. I PLAN ON CHIPPING IT OFF AS MUCH AS I CAN, SANDING IT AND THEN GETTING SOME BLACK PLASTISOL COATING. LUCKILY AGAIN MY EXPEDITION IS BLACK AND THE PROBLEM IS BETWEEN THE LUGGAGE RACK RUNNERS AND SUNROOF. *TR
NHTSA ODI #10284085
101,000 miles · Sep 9, 2009
Visibility
I HAVE A 2005 FORD EXPEDITION XLT (100K MILES, V8, A-TRANS). THE DRIVERS SIDE WINDOW IS STUCK PERMANENTLY IN THE OPEN POSITION. I AM TOLD THE REGULATOR IS BROKEN AND MUST BE REPLACED. *TR
NHTSA ODI #10283388
120,000 miles · Aug 18, 2009
Vehicle Speed Control
OWN A 2005 FORD EXPEDITION, IN THE PAST 6 MONTHS AT ABOUT A RATE OF ONCE/MONTH THE ENGINE WILL SHUT OFF LOSS OF POWER WITH DIFFICULTY STEERING, THE VEHICLE HAS INDICATED THAT THE ELECTRONIC THROTTLE CONTROL IS THE ISSUE. ONCE I'M ABLE TO COAST THE VEHICLE TO THE SIDE OF THE ROAD I SHUT OFF THE VEHICLE AND RESTART WITHIN A FEW M…
Read full complaint
OWN A 2005 FORD EXPEDITION, IN THE PAST 6 MONTHS AT ABOUT A RATE OF ONCE/MONTH THE ENGINE WILL SHUT OFF LOSS OF POWER WITH DIFFICULTY STEERING, THE VEHICLE HAS INDICATED THAT THE ELECTRONIC THROTTLE CONTROL IS THE ISSUE. ONCE I'M ABLE TO COAST THE VEHICLE TO THE SIDE OF THE ROAD I SHUT OFF THE VEHICLE AND RESTART WITHIN A FEW MINUTES AND ABLE TO CONTINUE UNTIL THE NEXT INCIDENT WITH THIS PROBLEM. I HAVE RESEARCHED THROUGH THE INTERNET AND HAVE FOUND NUMEROUS COMPLAINTS IN REFERENCE TO THIS SAME ISSUE WITH SOME INVOLVING ACCIDENTS DUE TO THE INADVERTENT LOSS OF POWER. I HAVE CONTACTED THE FORD MOTOR COMPANY AND THEY WILL ONLY TELL ME THAT THEY WILL NOT DO ANYTHING TO COVER THIS. THIS IS A SERIOUS SAFETY ISSUE AND NEEDS TO BE ADDRESSED BEFORE SOMEONE IS KILLED IN A MOTOR VEHICLE ACCIDENT DUE TO THIS PROBLEM. *TR
NHTSA ODI #10280894
38,000 miles · Aug 13, 2009
Structure
THE PAINT IS BUBBLING AND PEELING ON THE HOOD AND REAR LIFT GATE. THIS PROBLEM STARTED AND KEEPS GETTING WORSE. THE PAINT HAS ALREADY CAME OFF IN A 1 INCH SECTION. I COULD SEND I A PIECE OF THE PAINT TO A LAB IF NEEDED. CAR WAS NEVER IN ACCIDENT OF RE-PAINTED. *TR
NHTSA ODI #10280309
64,000 miles · Aug 3, 2009
TiresCrash
TL*THE CONTACT OWNS A 2005 FORD EXPEDITION. WHILE DRIVING 55 MPH, THREE OUT OF THE FOUR TIRES FLATTENED AND CAUSED THE CONTACT TO CRASH INTO A CONCRETE WALL. A POLICE REPORT WAS FILED AND THE VEHICLE WAS TOWED FROM THE SCENE. THERE WERE NO INJURIES. THE INSURANCE COMPANY IS INVESTIGATING THE CAUSE OF THE TIRE FAILURE. THE C…
Read full complaint
TL*THE CONTACT OWNS A 2005 FORD EXPEDITION. WHILE DRIVING 55 MPH, THREE OUT OF THE FOUR TIRES FLATTENED AND CAUSED THE CONTACT TO CRASH INTO A CONCRETE WALL. A POLICE REPORT WAS FILED AND THE VEHICLE WAS TOWED FROM THE SCENE. THERE WERE NO INJURIES. THE INSURANCE COMPANY IS INVESTIGATING THE CAUSE OF THE TIRE FAILURE. THE CURRENT AND FAILURE MILEAGES WERE 64,000.
NHTSA ODI #10279238
37,000 miles · Jul 17, 2009
Structure
I HAVE A 2005 EXPEDITION EDDIE BAUER AND THE LIFT GATE WILL OPEN ON OCCASION. THE DEALER CANNOT FIND ANYTHING WRONG TO CAUSE THIS BUT IS AWARE OF OTHER COMPLAINTS. I BOUGHT THE VEHICLE BRAND NEW AND STARTED TO ENCOUNTER THIS PROBLEM AT 37,000 MILES WHEN THE WARRANTY RAN OUT. I AM AFRAID THIS WILL HAPPEN WHILE I AM TRANSPORTI…
Read full complaint
I HAVE A 2005 EXPEDITION EDDIE BAUER AND THE LIFT GATE WILL OPEN ON OCCASION. THE DEALER CANNOT FIND ANYTHING WRONG TO CAUSE THIS BUT IS AWARE OF OTHER COMPLAINTS. I BOUGHT THE VEHICLE BRAND NEW AND STARTED TO ENCOUNTER THIS PROBLEM AT 37,000 MILES WHEN THE WARRANTY RAN OUT. I AM AFRAID THIS WILL HAPPEN WHILE I AM TRANSPORTING MY DOGS TO A DOG SHOW AND THEIR CRATES WILL BE THROWN OUT OF THE REAR ONTO THE HIGHWAY. *TR
NHTSA ODI #10277089
57,000 miles · Jul 14, 2009
SeatsVisibility
TL*THE CONTACT OWNS A 2005 FORD EXPEDITION. THE CONTACT STATED THAT BOTH THE FRONT DRIVER'S AND PASSENGER SEATS WOULD NOT MOVE UP AND DOWN. IN ADDITION, THE FRONT PASSENGER WINDOW WAS THE FIRST TO SUDDENLY STOP WORKING. WITHIN SIX MONTHS, THE FRONT DRIVER'S SIDE WINDOW ALSO BEGAN TO FAIL. THE VEHICLE IS CURRENTLY AT THE DEAL…
Read full complaint
TL*THE CONTACT OWNS A 2005 FORD EXPEDITION. THE CONTACT STATED THAT BOTH THE FRONT DRIVER'S AND PASSENGER SEATS WOULD NOT MOVE UP AND DOWN. IN ADDITION, THE FRONT PASSENGER WINDOW WAS THE FIRST TO SUDDENLY STOP WORKING. WITHIN SIX MONTHS, THE FRONT DRIVER'S SIDE WINDOW ALSO BEGAN TO FAIL. THE VEHICLE IS CURRENTLY AT THE DEALER, BUT THEY ARE NOT ASSUMING RESPONSIBILITY FOR THE REPAIRS. THE CONTACT BELIEVES THAT THIS IS A MANUFACTURER DEFECT. THE VIN WAS UNKNOWN. THE FAILURE MILEAGE WAS 57,000 AND CURRENT MILEAGE WAS 63,000.
NHTSA ODI #10276753
78,000 miles · Jul 12, 2009
Electrical System
ELECTRIC THROTTLE CONTROL WENT OUT WHILE DRIVING AST 60 MPH ALSO IGNITION FUSE WENT OUT SO CAR WAS DEAD LEAVING ME STRANDED IN THE MIDDLE OF NO WHERE WITH 4 GIRLS IN THE CAR. THE ENGINE LITERALLY STOPPED WHILE I WAS DRIVING AT 60 MPH. COULD HAVE BEEN VERY DANGEROUS IF ON A CROWDED INTERSTATE. *TR
NHTSA ODI #10276440
74,880 miles · Jun 19, 2009
Electronic Stability Control (esc)
WAS DRIVING DOWN A 4 LANE HEAVY TRAFFIC ROAD IN FAIR WEATHER CONDITIONS AROUND 45 MPH WHEN VEHICLE MAINTENANCE LIGHT "CHECK ELECTRONIC THROTTLE CONTROL" CAME ON AND COMPLETELY SHUT OFF ANY DRIVING POWER TO MY VEHICLE. I WAS NOT EVEN ABLE TO ACCELERATE TO PULL OVER SAFELY. I WAS DRIVING WITH A 3 YEAR OLD AND I AM ALSO 6 MONTHS PR…
Read full complaint
WAS DRIVING DOWN A 4 LANE HEAVY TRAFFIC ROAD IN FAIR WEATHER CONDITIONS AROUND 45 MPH WHEN VEHICLE MAINTENANCE LIGHT "CHECK ELECTRONIC THROTTLE CONTROL" CAME ON AND COMPLETELY SHUT OFF ANY DRIVING POWER TO MY VEHICLE. I WAS NOT EVEN ABLE TO ACCELERATE TO PULL OVER SAFELY. I WAS DRIVING WITH A 3 YEAR OLD AND I AM ALSO 6 MONTHS PREGNANT. WHEN THE CAR FINALLY STOPPED ITSELF, I SHUT THE ENGINE OFF, WAITED A MINUTE AND STARTED IT UP AGAIN. IT STARTED ROUGHLY, BUT THEN WAS FINE. CALLED FOX FORD DEALERSHIP IN GRAND RAPIDS, MI THAT I NORMALLY DEAL WITH AND THEY SAID THAT IT WOULD BE THE THROTTLE BODY WITH THROTTLE CONTROL SENSORS IN IT. MY TYPE OF WARRANTY (POWERTRAIN) DOES NOT COVER IT AND IT WILL RUN BETWEEN $500 - $700 TO FIX IT. CONTACTED FORD ITSELF. THERE IS NO RECALL ON THIS ITEM, ALTHOUGH I'VE NOTICED TONS OF COMPLAINTS ON THE INTERNET ABOUT IT. HTTP://WWW.FIXYA.COM/CARS/T1061679-ELECTRONIC_THROTTLE_CONTROL_LIGHT_CAME HAS AT LEAST 4 RIGHT THERE. THIS IS A VERY DANGEROUS PROBLEM. LUCKILY I WAS NOT DRIVING 70 MILES AN HOUR ON THE HIGHWAY WHEN THIS HAPPENED. THIS NEEDS TO BE RECALLED DUE TO SAFETY HAZARDS. I SEE IT CAUSING A MAJOR ACCIDENT IN THE FUTURE IF IT HASN'T ALREADY. THERE ARE TONS OF DO-IT-YOURSELF FIX-IT SITES WITH TONS OF PEOPLE REPORTING THIS SAME PROBLEM WITH THIS SAME YEAR VEHICLE. I DON'T SEE WHY IT HASN'T BEEN RECALLED YET. THIS IS DANGEROUS!! HOW CAN THEY EXPECT FAMILIES TO BE DRIVING SAFELY JUST TO BE SHUT OFF BY IT'S OWN VEHICLE THAT'S ONLY 4 YEARS OLD!! RIDICULOUS! *TR
NHTSA ODI #10274350
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