NHTSA owner reports · September 18, 2026 snapshot.
What owners actually said
315 reports69,890 miles · Jun 19, 2009
Engine And Engine Cooling
I RECENTLY TOOK MY 2005 FORD EXPEDITION FOR A TUNE-UP AT A LOCAL SHOP. THE OWNER OF THE SHOP TOLD ME THAT THE SPARK PLUG IN CYLINDER #4 BROKE AND IS STUCK IN THE ENGINE. THE SAFEST WAY TO REMEDY THE PROBLEM IS TO TAKE THE ENGINE HEAD OFF TO TAKE OUT THE BROKEN SPARK PLUG. I DID A RESEARCH ON THE INTERNET AND FOUND THAT FORD'S …
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I RECENTLY TOOK MY 2005 FORD EXPEDITION FOR A TUNE-UP AT A LOCAL SHOP. THE OWNER OF THE SHOP TOLD ME THAT THE SPARK PLUG IN CYLINDER #4 BROKE AND IS STUCK IN THE ENGINE. THE SAFEST WAY TO REMEDY THE PROBLEM IS TO TAKE THE ENGINE HEAD OFF TO TAKE OUT THE BROKEN SPARK PLUG. I DID A RESEARCH ON THE INTERNET AND FOUND THAT FORD'S DESIGN OF THE SPARK PLUGS CAUSES THE THREAD TO SEPARATE FROM THE SPARK PLUG ITSELF LEADING TO THE BREAKING OF THE PLUGS. THERE ARE ALSO INSTANCES WHERE THE SPARK PLUG IS EJECTED FROM THE ENGINE. I TRIED TO FILE A COMPLAINT WITH FORD MOTOR COMPANY; HOWEVER, THEY REFUSED TO CALL IT A DEFECT IN THEIR SPARK PLUG DESIGNS. *TR
NHTSA ODI #10274319
89,923 miles · Jun 17, 2009
Electrical System
WHILE DRIVING OUR 2005 FORD EXPEDITION THE "CHECK THROTTLE" LIGHT CAME ON. THE CAR IMMEDIATELY QUIT RUNNING AND FORTUNATELY I WAS ABLE TO COAST TO A STOP. WE CALLED OUR FORD DEALERSHIP AND WAS TOLD THEY THOUGHT A RECALL HAD BEEN ISSUED FOR THIS PROBLEM. WE TOOK THE CAR TO THE FORD DEALERSHIP AND WAS TOLD THEN THAT THEY COULD N…
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WHILE DRIVING OUR 2005 FORD EXPEDITION THE "CHECK THROTTLE" LIGHT CAME ON. THE CAR IMMEDIATELY QUIT RUNNING AND FORTUNATELY I WAS ABLE TO COAST TO A STOP. WE CALLED OUR FORD DEALERSHIP AND WAS TOLD THEY THOUGHT A RECALL HAD BEEN ISSUED FOR THIS PROBLEM. WE TOOK THE CAR TO THE FORD DEALERSHIP AND WAS TOLD THEN THAT THEY COULD NOT FIND A RECALL FOR THIS PROBLEM. IT COSTS US $626.37. WE HAVE SINCE LEARNED THAT THERE HAVE BEEN NUMEROUS COMPLAINTS ABOUT THIS SAME PROBLEM ON 2005 FORD EXPEDITIONS. WAS TOLD WHEN WE CALLED FORD HEADQUARTERS THAT WE NEEDED TO FILE A COMPLAINT. *TR
NHTSA ODI #10274123
38,000 miles · Jun 2, 2009
Power Train
WHILE DRIVING WITH A SMALL CHILD IN THE CAR - LESS THAN 15MPH NEAR A RESIDENTIAL AREA - MY 2005 FORD EXPEDITION LTD SUDDENLY FLASHED AN ERROR MESSAGE "CHECK ELECTRONIC THROTTLE CONTROL" AND IMMEDIATELY LOST ACCELERATION, BRAKING AND STEERING. I WAS ABLE TO VEER THE VEHICLE TO THE SIDE OF THE ROAD WITHOUT CAUSING AN ACCIDENT. I…
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WHILE DRIVING WITH A SMALL CHILD IN THE CAR - LESS THAN 15MPH NEAR A RESIDENTIAL AREA - MY 2005 FORD EXPEDITION LTD SUDDENLY FLASHED AN ERROR MESSAGE "CHECK ELECTRONIC THROTTLE CONTROL" AND IMMEDIATELY LOST ACCELERATION, BRAKING AND STEERING. I WAS ABLE TO VEER THE VEHICLE TO THE SIDE OF THE ROAD WITHOUT CAUSING AN ACCIDENT. I USED THE EMERGENCY BRAKE TO STOP THE VEHICLE AT WHICH TIME I MANUALLY TURNED OFF THE IGNITION. WAITED A FEW MOMENTS, AND MANAGED TO GET THE VEHICLE STARTED AND RUNNING AGAIN. THERE WAS ABSOLUTELY NO WARNING AND THE VEHICLE GIVES YOU NO OPPORTUNITY TO GET THE VEHICLE PULLED OVER SAFELY BEFORE DISENGAGING. THIS APPEARS TO BE A VERY SERIOUS AND DANGEROUS SUDDEN MECHANICAL FAILURE. *TR
NHTSA ODI #10272672
85,000 miles · Jun 2, 2009
Air BagsCrashInjury
TL*THE CONTACT OWNS A 2005 FORD EXPEDITION. WHILE DRIVING BETWEEN 55-60 MPH, A TRACTOR TRAILER MERGED OVER AND CAUSED THE CONTACT TO CRASH INTO A TREE. NONE OF THE AIR BAGS DEPLOYED IN THE VEHICLE. THE CONTACT SUSTAINED FACIAL INJURIES AND THREE OTHER PASSENGERS SUSTAINED MINOR INJURIES. ONE OCCUPANT SUFFERED MAJOR INJURIES.…
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TL*THE CONTACT OWNS A 2005 FORD EXPEDITION. WHILE DRIVING BETWEEN 55-60 MPH, A TRACTOR TRAILER MERGED OVER AND CAUSED THE CONTACT TO CRASH INTO A TREE. NONE OF THE AIR BAGS DEPLOYED IN THE VEHICLE. THE CONTACT SUSTAINED FACIAL INJURIES AND THREE OTHER PASSENGERS SUSTAINED MINOR INJURIES. ONE OCCUPANT SUFFERED MAJOR INJURIES. THE VEHICLE WAS DESTROYED. THERE WAS ADDITIONAL PROPERTY DAMAGE TO THE HIGHWAY MEDIAN. A POLICE REPORT WAS FILED. ALL OF THE PASSENGERS WERE WEARING SEAT BELTS AT THE TIME OF THE CRASH. THERE WERE NO REPAIRS MADE TO THE AIR BAGS PRIOR TO THE CRASH. THE VEHICLE HAS NOT BEEN INSPECTED BY A DEALER. THE CONTACT'S INSURANCE COMPANY IS REVIEWING THE DAMAGE AND SENDING A RECONSTRUCTIONIST TO INVESTIGATE. THE CURRENT AND FAILURE MILEAGES WERE 85,000.
NHTSA ODI #10272628
57,000 miles · Jun 1, 2009
Electronic Stability Control (esc)
I WAS DRIVING MY CAR WHEN ELECTRONIC THROTTLE CONTROL LIGHT CAME ON AND MY CAR LOST POWER INSTANTLY AND STALLED. I HAVE 57,000 MILES ON MY CAR. I AM NOT COVERED UNDER WARRANTY BUT DUE TO THE NATURE OF THE PROBLEM, I FIGURED FORD WOULD HAVE RECALLED THIS FAULTY PART BECAUSE OF SAFETY CONCERNS. I TRAVEL DAILY WITH 3 CHILDREN AND T…
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I WAS DRIVING MY CAR WHEN ELECTRONIC THROTTLE CONTROL LIGHT CAME ON AND MY CAR LOST POWER INSTANTLY AND STALLED. I HAVE 57,000 MILES ON MY CAR. I AM NOT COVERED UNDER WARRANTY BUT DUE TO THE NATURE OF THE PROBLEM, I FIGURED FORD WOULD HAVE RECALLED THIS FAULTY PART BECAUSE OF SAFETY CONCERNS. I TRAVEL DAILY WITH 3 CHILDREN AND THIS PROBLEM HAPPENED TO ME TWICE BEFORE I TOOK IT IN TO DEALERSHIP. THANKFULLY NO ONE WAS BEHIND ME BOTH TIMES. I HAD TO PAY OVER $500 TO HAVE THE PART REPLACED. I CALLED FORD TO EXPRESS MY CONCERN AND THEY BASICALLY DID NOTHING BUT TAKE MY INFORMATION AND THEN TURN THE CALL INTO A SALES EFFORT. THEY ADVISED ME THERE WERE GREAT PROMOTIONS AND REBATES ON NEW VEHICLES RIGHT NOW. LIKE I WOULD WANT TO BUY A FORD AGAIN WHEN THEY HAVE NO REGARD FOR CONSUMER SAFETY!!! *TR
NHTSA ODI #10272517
29,000 miles · May 13, 2009
Visibility
2005 FORD EXPEDITION DRIVERS SIDE WINDOW REGULATOR BROKE AND WINDOW DROPPED INTO DOOR PANEL WITH A LOUD CRASHING SOUND WHILE DRIVING. I'M REPORTING THIS TO YOU BECAUSE OF SEVERAL OTHER REPORTS I FOUND ON-LINE REGARDING THE SAME ISSUE. THIS SEEMS TO BE A RECURRING SAFETY PROBLEM THAT NEEDS TO BE LOOKED INTO, AND POSSIBLY A RECALL…
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2005 FORD EXPEDITION DRIVERS SIDE WINDOW REGULATOR BROKE AND WINDOW DROPPED INTO DOOR PANEL WITH A LOUD CRASHING SOUND WHILE DRIVING. I'M REPORTING THIS TO YOU BECAUSE OF SEVERAL OTHER REPORTS I FOUND ON-LINE REGARDING THE SAME ISSUE. THIS SEEMS TO BE A RECURRING SAFETY PROBLEM THAT NEEDS TO BE LOOKED INTO, AND POSSIBLY A RECALL ISSUE. *TR
NHTSA ODI #10268599
65,120 miles · May 6, 2009
Engine And Engine Cooling
WHILE DRIVING ON TWO SEPARATE OCCASIONS SUDDENLY THE CHECK ENGINE THROTTLE CONTROL LIGHT HAS COME ONE. UPON SAFELY PULLING OVER AND RESTARTING THE CAR THE LIGHT GOES OFF AND APPARENTLY THE THROTTLE RESETS. THE DANGER IS THAT WHEN THE LIGHT COMES ON THE CAR GOES INTO IDLE ONLY MODE. NO ACCELERATING, ETC. THERE IS NO WARNING THAT …
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WHILE DRIVING ON TWO SEPARATE OCCASIONS SUDDENLY THE CHECK ENGINE THROTTLE CONTROL LIGHT HAS COME ONE. UPON SAFELY PULLING OVER AND RESTARTING THE CAR THE LIGHT GOES OFF AND APPARENTLY THE THROTTLE RESETS. THE DANGER IS THAT WHEN THE LIGHT COMES ON THE CAR GOES INTO IDLE ONLY MODE. NO ACCELERATING, ETC. THERE IS NO WARNING THAT THIS IS GOING TO HAPPEN AND NO OTHER REMEDY. THE FIRST TIME I WAS IN A CARPOOL SETTING IDLING. THE SECOND TIME I HAD JUST GOTTEN OFF THE INTERSTATE AND WAS ABLE TO PULL INTO A SHOPPING CENTER. THIS IS A MAJOR SAFETY CONCERN IF IT HAPPENS ON THE INTERSTATE. I HAVE TAKEN THE CAR IN TO HAVE A DIAGNOSTIC EVALUATION AND THERE IS NO KNOWN CAUSE OF THE FAILURE. AFTER READING 100S OF SIMILAR COMPLAINTS ONLINE IT IS APPARENT THIS IS A PROBLEM FOR THE MAKE AND MODEL THAT NEEDS TO BE INVESTIGATED. *TR
NHTSA ODI #10267863
35,000 miles · May 6, 2009
Engine And Engine Cooling
2005 FORD EXPEDITION WITH ERROR MESSAGE OF 'CHECK ELECTRONIC THROTTLE CONTROL'. IT HAS HAPPENED 5 TIMES NOW. ENGINE, STEERING AND BRAKING STOP WORKING INSTANTLY. I HAVE TO SHUT TRUCK OFF TO RESTART. ALL TIMES IT HAS HAPPENED WHILE GOING 60-70 MILES AN HOUR ON HIGHWAY. FORD HAS CHARGED ME OVER $1200 TO THIS DAY FOR FIXES, BU…
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2005 FORD EXPEDITION WITH ERROR MESSAGE OF 'CHECK ELECTRONIC THROTTLE CONTROL'. IT HAS HAPPENED 5 TIMES NOW. ENGINE, STEERING AND BRAKING STOP WORKING INSTANTLY. I HAVE TO SHUT TRUCK OFF TO RESTART. ALL TIMES IT HAS HAPPENED WHILE GOING 60-70 MILES AN HOUR ON HIGHWAY. FORD HAS CHARGED ME OVER $1200 TO THIS DAY FOR FIXES, BUT NOTHING HAS FIXED THE PROBLEM. THEY ALSO HAVE NO ANSWER AS TO WHY IT KEEPS RECURRING. WHEN THEY HOOK IT UP TO THE COMPUTER, THEY SAY THERE ARE NO ERROR CODES. *TR
NHTSA ODI #10267820
56,000 miles · May 1, 2009
Fuel System, Gasoline
2005 FORD EXPEDITION WILL DIE WHILE DRIVING AND A WRENCH LIGHT APPEARS ON THE DASH. THIS HAS HAPPENED MORE THAN 5 TIMES IN THE LAST MONTH. THE DEALER HAS STATED THAT THERE ARE THOUSANDS OF THESE OCCURRENCES WITH THE THROTTLE BODY NEEDING TO BE REPLACED AT AN $800 OWNERS EXPENSE. THE EXPEDITION IS NOT THE ONLY MODEL HAVING THI…
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2005 FORD EXPEDITION WILL DIE WHILE DRIVING AND A WRENCH LIGHT APPEARS ON THE DASH. THIS HAS HAPPENED MORE THAN 5 TIMES IN THE LAST MONTH. THE DEALER HAS STATED THAT THERE ARE THOUSANDS OF THESE OCCURRENCES WITH THE THROTTLE BODY NEEDING TO BE REPLACED AT AN $800 OWNERS EXPENSE. THE EXPEDITION IS NOT THE ONLY MODEL HAVING THIS PROBLEM. *TR
NHTSA ODI #10267488
64,843 miles · Apr 27, 2009
Electrical System
THIS IS THE 5TH TIME THIS PARTICULAR MALFUNCTION HAS OCCURRED WITHIN A 4 MONTH PERIOD. WHILE CRUISING AT LOW SPEED (5-15 MPH) IN STOP AND GO TRAFFIC, THE ENGINE LIGHT ILLUMINATES AND THE VEHICLE SHUTS DOWN. WITH THE VEHICLE ENGINE OFF THERE ISN'T ANY POWER STEERING AND DRIVER MUST MANEUVER SAFELY TO THE SIDE OF THE ROAD AND COME…
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THIS IS THE 5TH TIME THIS PARTICULAR MALFUNCTION HAS OCCURRED WITHIN A 4 MONTH PERIOD. WHILE CRUISING AT LOW SPEED (5-15 MPH) IN STOP AND GO TRAFFIC, THE ENGINE LIGHT ILLUMINATES AND THE VEHICLE SHUTS DOWN. WITH THE VEHICLE ENGINE OFF THERE ISN'T ANY POWER STEERING AND DRIVER MUST MANEUVER SAFELY TO THE SIDE OF THE ROAD AND COME TO A COMPLETE STOP, PLACE VEHICLE IN PARK AND RESTART THE ENGINE. THE ERROR MESSAGE IS ABOUT THE THROTTLE CONTROL AND THE VEHICLE IS ONLY 4 YEARS OLD WITH 64,000 MILES. THIS IS A SAFETY CONCERN ESPECIALLY AT HIGH RATES OF SPEED AND THE PART IS NOT COVERED BY THE VEHICLE WARRANTY. I WENT TO THE FORD DEALER WHERE WE PURCHASED VEHICLE AND WAS CHARGED $684.00 TO REPLACE THE ELECTRONIC THROTTLE CONTROL. THAT'S WHEN I LEARNED THAT THIS MALFUNCTION HAS RECENTLY BEEN OCCURRING ON SEVERAL 2005 FORD EXPEDITION VEHICLES IN THE LAST 6 MONTHS. APPARENTLY, THERE IS NO FORD RECALL FOR THIS PART AND IT IS A TRUE SAFETY CONCERN FOR ALL FORD EXPEDITION OWNERS. *TR
NHTSA ODI #10266993
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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