NHTSA owner reports · September 18, 2026 snapshot.
What owners actually said
315 reports63,700 miles · Apr 20, 2009
Power Train
MY 05 FORD EXPEDITION WAS RECENTLY IN THE SHOP SEVERAL MONTHS BACK FOR ELECTRONIC THROTTLE ISSUES. TONIGHT THE CHECK ELECTRONIC THROTTLE LIGHT CAME ON AND CAUSED A TOTAL LOSS OF ACCELERATION. I PUT MY HAZARDS ON AND COASTED TO THE SIDE OF THE ROAD. AFTER TURNING OFF MY ENGINE AND RESTARTING MY VEHICLE RUNS LIKE NORMAL AGAIN. LUC…
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MY 05 FORD EXPEDITION WAS RECENTLY IN THE SHOP SEVERAL MONTHS BACK FOR ELECTRONIC THROTTLE ISSUES. TONIGHT THE CHECK ELECTRONIC THROTTLE LIGHT CAME ON AND CAUSED A TOTAL LOSS OF ACCELERATION. I PUT MY HAZARDS ON AND COASTED TO THE SIDE OF THE ROAD. AFTER TURNING OFF MY ENGINE AND RESTARTING MY VEHICLE RUNS LIKE NORMAL AGAIN. LUCKILY IT WAS VERY LATE AT NIGHT AND NO OTHER CARS WERE AROUND. THIS IS POTENTIALLY VERY DANGEROUS IF IT OCCURS IN FAST MOVING TRAFFIC. I HAVE RESEARCHED THIS ISSUE AND SEE COUNTLESS POSTS ON INTERNET FORUMS FROM 05 FORD EXPEDITION OWNERS DETAILING MY EXACT ISSUE AND TEMPORARY SOLUTION. WHEN IS THIS GOING TO BE OFFICIALLY ACKNOWLEDGED BY FORD AS A SERIOUS DEFECT AND RECALLED? *TR
NHTSA ODI #10266042
75,000 miles · Apr 15, 2009
Engine And Engine Cooling
WHILE DRIVING THE CAR ON THE HIGHWAY WITH CHILDREN IN THE VEHICLE, THE ENGINE LIGHT CAME ON, MESSAGE CAME ON ABOUT ELECTRONIC THROTTLE CONTROL , AND THE VEHICLE LOST ALL FUNCTIONS OF STEERING, BRAKING, AND ACCELERATING. THERE WERE NO WARNINGS BEFORE THIS HAPPENED. AFTER TAKING IT TO THE FORD DEALER TODAY, I SEE ON THE INTERNE…
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WHILE DRIVING THE CAR ON THE HIGHWAY WITH CHILDREN IN THE VEHICLE, THE ENGINE LIGHT CAME ON, MESSAGE CAME ON ABOUT ELECTRONIC THROTTLE CONTROL , AND THE VEHICLE LOST ALL FUNCTIONS OF STEERING, BRAKING, AND ACCELERATING. THERE WERE NO WARNINGS BEFORE THIS HAPPENED. AFTER TAKING IT TO THE FORD DEALER TODAY, I SEE ON THE INTERNET THAT MANY MANY MANY FAMILIES ARE HAVING THIS SAME PROBLEM WITH 2005 FORD EXPEDITIONS. SEEING AS THE PROBLEM CREATES AN IMMEDIATE SAFETY CONCERN FOR NOT ONLY THE FAMILY IN THE 2005 FORD EXPEDITION, BUT ALL THE FAMILIES TRAVELING AROUND THE 2005 FORD EXPEDITION... I FEEL LIKE THE SAFETY BOARD SHOULD LOOK INTO THIS AS A POTENTIAL RECALL FOR 2005 FORD EXPEDITIONS. THANKFULLY MY FAMILY IS SAFE TODAY...BUT SOMEONE'S FAMILY MAY NOT BE SO LUCKY. *TR
NHTSA ODI #10265518
60,400 miles · Apr 11, 2009
Power Train
2005 FORD EXPEDITION WAS STOPPED AT STOP SIGN. "CHECK ELECTRONIC THROTTLE CONTROL" MESSAGE WAS DISPLAYED ON MESSAGE CENTER, ALONG WITH AN ANNUNCIATING "DING". ENGINE CONTINUED TO RUN, BUT ACCELERATOR PEDAL WAS COMPLETELY DEAD. SHUT OFF IGNITION AND RESTARTED VEHICLE, AND ACCELERATOR CONTROL RETURNED TO NORMAL. THERE WAS ONE OCCU…
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2005 FORD EXPEDITION WAS STOPPED AT STOP SIGN. "CHECK ELECTRONIC THROTTLE CONTROL" MESSAGE WAS DISPLAYED ON MESSAGE CENTER, ALONG WITH AN ANNUNCIATING "DING". ENGINE CONTINUED TO RUN, BUT ACCELERATOR PEDAL WAS COMPLETELY DEAD. SHUT OFF IGNITION AND RESTARTED VEHICLE, AND ACCELERATOR CONTROL RETURNED TO NORMAL. THERE WAS ONE OCCURRENCE SO FAR. *TR
NHTSA ODI #10265001
59,991 miles · Apr 7, 2009
Power Train
TL*THE CONTACT OWNS A 2005 FORD EXPEDITION. WHILE DRIVING APPROXIMATELY 10 MPH ON NORMAL ROAD CONDITIONS, THERE WAS NO RESPONSE WHEN THE ACCELERATOR PEDAL WAS DEPRESSED. AN UNKNOWN WARNING INDICATOR ILLUMINATED ON THE INSTRUMENT PANEL INTERMITTENTLY. ROADSIDE ASSISTANCE WAS CALLED TO THE SCENE AND THE VEHICLE WAS TOWED TO AN …
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TL*THE CONTACT OWNS A 2005 FORD EXPEDITION. WHILE DRIVING APPROXIMATELY 10 MPH ON NORMAL ROAD CONDITIONS, THERE WAS NO RESPONSE WHEN THE ACCELERATOR PEDAL WAS DEPRESSED. AN UNKNOWN WARNING INDICATOR ILLUMINATED ON THE INSTRUMENT PANEL INTERMITTENTLY. ROADSIDE ASSISTANCE WAS CALLED TO THE SCENE AND THE VEHICLE WAS TOWED TO AN AUTHORIZED DEALER FOR INSPECTION. THE TECHNICIAN STATED THAT THE TRANSMISSION FAILED. THE DEALER REPLACED THE AUTOMATIC TRANSMISSION. THE FAILURE MILEAGE WAS 59,991 AND CURRENT MILEAGE IS 62,000. UPDATED 05/06/09. *LJ UPATED 05/07/09.*JB
NHTSA ODI #10264350
52,000 miles · Apr 6, 2009
Electrical SystemVehicle Speed Control
I WAS DRIVING 55MPH ON HIGHWAY, WHEN ALL OF A SUDDEN THERE WAS NO POWER TO GAS PEDAL. THE CHECK ELECTRONIC THROTTLE CONTROL LIGHT FLASHED, I PULLED OVER THREE LANES TO SIDE OF ROAD. I SAT THERE TRYING TO START VEHICLE CONTINUOUSLY, FINALLY AFTER 10 MINUTES IT STARTED. MY 9 MONTH OLD DAUGHTER AND I WAS ALMOST KILLED ON THE HIGHWA…
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I WAS DRIVING 55MPH ON HIGHWAY, WHEN ALL OF A SUDDEN THERE WAS NO POWER TO GAS PEDAL. THE CHECK ELECTRONIC THROTTLE CONTROL LIGHT FLASHED, I PULLED OVER THREE LANES TO SIDE OF ROAD. I SAT THERE TRYING TO START VEHICLE CONTINUOUSLY, FINALLY AFTER 10 MINUTES IT STARTED. MY 9 MONTH OLD DAUGHTER AND I WAS ALMOST KILLED ON THE HIGHWAY DUE TO THIS PROBLEM. MY VEHICLE IS NOW RUNNING TERRIBLE. I CAME HOME TO SEE IF I COULD FIND ANYTHING ON THE INTERNET AND FOUND THAT THIS IS COMMON IN THE 2005 FORD EXPEDITION AND NOTHING IS BEING DONE. IS IT GOING TO TAKE SOMEONE GETTING KILLED FOR FORD TO RECALL THIS PROBLEM? IT OBVIOUSLY IS A MANUFACTURING PROBLEM AND THEY ARE DOING NOTHING ABOUT IT. I WILL BE CONTACTING FORD TOMORROW TO SEE ABOUT GETTING MY VEHICLE IN AND FIXING THIS. *TR
NHTSA ODI #10264202
40,852 miles · Apr 5, 2009
Electrical System
AS I WAS DRIVING TO MY OFFICE SHORTLY AFTER NOON TODAY, AN ALERT APPEARED "CHECK ELECTRONIC THROTTLE SYSTEM." MY EXPEDITION WOULD NOT ACCELERATE, I COASTED INTO A PARKING LOT AND TRIED TO ACCELERATE, BUT NOTHING HAPPENED. I TURNED OFF THE ENGINE AND RESTARTED MY VEHICLE - I COULD THEN ACCELERATE MY VEHICLE AND CONTINUED TO MY …
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AS I WAS DRIVING TO MY OFFICE SHORTLY AFTER NOON TODAY, AN ALERT APPEARED "CHECK ELECTRONIC THROTTLE SYSTEM." MY EXPEDITION WOULD NOT ACCELERATE, I COASTED INTO A PARKING LOT AND TRIED TO ACCELERATE, BUT NOTHING HAPPENED. I TURNED OFF THE ENGINE AND RESTARTED MY VEHICLE - I COULD THEN ACCELERATE MY VEHICLE AND CONTINUED TO MY OFFICE. THIS IS WAS A VERY SCARY INCIDENT, THANKFULLY I WAS THE ONLY ONE IN MY VEHICLE TODAY; MY GRANDSON IS SOMETIMES WITH ME. I AM ALSO THANKFUL THAT I WAS IN THE RIGHT LANE, SO I WAS ABLE TO COAST INTO THE PARKING LOT. *TR
NHTSA ODI #10264196
69,900 miles · Mar 18, 2009
Engine And Engine Cooling
WHILE DRIVING MY 2005 FORD EXPEDITION (4 SEPARATE INCIDENTS) DOWN THE ROAD, A WARNING MESSAGE APPEARS ON THE MESSAGE CENTER TO "CHECK ELECTRONIC THROTTLE CONTROL". THE VEHICLE LOSES ALL ACCELERATION, ACCELERATOR DOES NOT WORK, I HAVE TO COAST TO THE SIDE OF THE ROAD, RESTART THE VEHICLE THEN IT RUNS FINE. VERY DANGEROUS, FORTU…
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WHILE DRIVING MY 2005 FORD EXPEDITION (4 SEPARATE INCIDENTS) DOWN THE ROAD, A WARNING MESSAGE APPEARS ON THE MESSAGE CENTER TO "CHECK ELECTRONIC THROTTLE CONTROL". THE VEHICLE LOSES ALL ACCELERATION, ACCELERATOR DOES NOT WORK, I HAVE TO COAST TO THE SIDE OF THE ROAD, RESTART THE VEHICLE THEN IT RUNS FINE. VERY DANGEROUS, FORTUNATELY NO ONE HURT AND NO DAMAGE. BUT IF THIS WOULD HAPPEN ON AN INTERSTATE IN THE LEFT LANE IN HEAVY TRAFFIC...?? VERY SCARY SITUATION! ACCORDING TO MY MECHANIC AND A FORD DEALERSHIP, THEY CANNOT FIND A CAUSE AND NO FAULT CODES COME UP IN COMPUTER. SUGGEST POSSIBLE FIX OF REPLACING THE THROTTLE BODY FOR ABOUT $700-800, WITH NO RESPONSIBILITY FROM FORD. *TR
NHTSA ODI #10262260
40,000 miles · Mar 15, 2009
Electrical System
ON MY 2005 FORD EXPEDITION I HAVE GOTTEN AN ALERT OF "CHECK ELECTRONIC THROTTLE SYSTEM". ON TWO OCCASIONS WHEN THIS ALERT HAS SOUNDED, THE VEHICLE HAS DIED OUT IN THE MIDDLE OF TRAVEL AND I HAD TO GET TO THE SIDE OF THE ROADWAY TO RESTART. ON TWO OTHER OCCASIONS WHEN THIS ALERT HAS SOUNDED, THE VEHICLE DID NOT DIE BUT I WAS NO…
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ON MY 2005 FORD EXPEDITION I HAVE GOTTEN AN ALERT OF "CHECK ELECTRONIC THROTTLE SYSTEM". ON TWO OCCASIONS WHEN THIS ALERT HAS SOUNDED, THE VEHICLE HAS DIED OUT IN THE MIDDLE OF TRAVEL AND I HAD TO GET TO THE SIDE OF THE ROADWAY TO RESTART. ON TWO OTHER OCCASIONS WHEN THIS ALERT HAS SOUNDED, THE VEHICLE DID NOT DIE BUT I WAS NOT ABLE TO ACCELERATE. I HAD TO STOP AND RESTART THE VEHICLE. THIS IS VERY DANGEROUS WHEN YOU ARE TRAVELING DOWN THE ROADWAY AND YOUR CAR EITHER DIES OUT OR LOSSES POWER. AFTER THE SECOND OCCURANCE I TOOK IT INTO THE DEALERSHIP AND WAS TOLD THAT THEY FOUND NOTHING WHEN HOOKED UP TO THE COMPUTER. THEY COULD DO NOTHING. THE VEHICLE RUNS FINE OTHER THAN THIS. THERE IS NO WARNING WHATSOEVER THAT THIS IS GOING TO OCCUR. *TR
NHTSA ODI #10261906
90,000 miles · Mar 11, 2009
Engine And Engine Cooling
CAR KEEPS DIES IN TRAFFIC ALMOST EVERYDAY AND THE ELECTRONIC THROTTLE CONTROL LIGHT KEEPS COMING ON . FORD WANTS $800 TO FIX. WITH THIS SAFETY ISSUE, I BELIEVE THERE SHOULD SOME SORT OF ACTION FORD SHOULD TAKE AND FIX THE PROBLEM SINCE IT IS ALWAYS HAPPENING TO THIS YEAR AND MODEL SO OFTEN. *TR
NHTSA ODI #10261589
60,135 miles · Mar 10, 2009
Vehicle Speed Control
2005 FORD EXPEDITION - LOSES COMPLETE POWER UNEXPECTEDLY. HAPPENS OFF-AND-ON. DIFFICULT TO RE-CREATE PROBLEM TO MECHANIC. BLOGS FULL OF SIMILAR EXPERIENCES. VERY UNSAFE CONDITION WHILE ON AN EXPRESSWAY. RECEIVE ERROR MESSAGE - "CHECK THROTTLE CONTROL". COST $500 TO REPLACE THROTTLE BODY. SEEMS TO BE POPULAR PROBLEM IN THE 2005 E…
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2005 FORD EXPEDITION - LOSES COMPLETE POWER UNEXPECTEDLY. HAPPENS OFF-AND-ON. DIFFICULT TO RE-CREATE PROBLEM TO MECHANIC. BLOGS FULL OF SIMILAR EXPERIENCES. VERY UNSAFE CONDITION WHILE ON AN EXPRESSWAY. RECEIVE ERROR MESSAGE - "CHECK THROTTLE CONTROL". COST $500 TO REPLACE THROTTLE BODY. SEEMS TO BE POPULAR PROBLEM IN THE 2005 EXPEDITION. *TR
NHTSA ODI #10261405
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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