NHTSA owner reports · September 18, 2026 snapshot.
What owners actually said
315 reports80,000 miles · Mar 5, 2009
Engine And Engine Cooling
2005 EXPEDITION EDDIE BAUER 4X4 - GOT A THROTTLE CONTROL ERROR MESSAGE, WAS TRAVELING AT ABOUT 55 MPH IN MORNING RUSH HOUR TRAFFIC ON A MAJOR HIGHWAY (DC/BALT) AND WAS LUCKY NOT TO GET SLAMMED INTO. VEHICLE ENGINE DIED, EVERYTHING ELSE WORKED. I SHUT IT ALL DOWN, TURNED THE KEY AND FIRED IT BACK UP AND IT IS RUNNING FINE AGAIN.…
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2005 EXPEDITION EDDIE BAUER 4X4 - GOT A THROTTLE CONTROL ERROR MESSAGE, WAS TRAVELING AT ABOUT 55 MPH IN MORNING RUSH HOUR TRAFFIC ON A MAJOR HIGHWAY (DC/BALT) AND WAS LUCKY NOT TO GET SLAMMED INTO. VEHICLE ENGINE DIED, EVERYTHING ELSE WORKED. I SHUT IT ALL DOWN, TURNED THE KEY AND FIRED IT BACK UP AND IT IS RUNNING FINE AGAIN. IT DID THE SAME THING ABOUT 5 MONTHS AGO. FORD SHOWS NO RECALLS. MY VEHICLE HAS BEEN PUT ON A COMPUTER AND NO ERROR CODES CAME UP. THE COMPUTER IS REPORTING NOTHING. THIS IS VERY DANGEROUS AND OTHER PEOPLE ARE REPORTING THE SAME PROBLEM... HTTP://WWW.FIXYA.COM/CARS/T1061679-ELECTRONIC_THROTTLE_CONTROL_LIGHT_CAME#SAMEPROBLEMCONTINUED. *TR
NHTSA ODI #10260829
Mileage unknown · Mar 2, 2009
Electrical System
WHILE DRIVING, CHECK ENGINE THROTTLE CONTROL LIGHT COMES ON. THE CAR ESSENTIALLY SHUTS DOWN - LOSES ACCELERATION, POWER STEERING, ETC. THIS HAS HAPPENED THREE TIMES...DECEMBER 10, 2008, FEBRUARY 23, 2009, AND MARCH 2, 2009. THE CAR WILL START AGAIN IF YOU TURN IT OFF AND RE-START IT. THIS CAN BE EXTREMELY DANGEROUS IF IT HAPPENS…
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WHILE DRIVING, CHECK ENGINE THROTTLE CONTROL LIGHT COMES ON. THE CAR ESSENTIALLY SHUTS DOWN - LOSES ACCELERATION, POWER STEERING, ETC. THIS HAS HAPPENED THREE TIMES...DECEMBER 10, 2008, FEBRUARY 23, 2009, AND MARCH 2, 2009. THE CAR WILL START AGAIN IF YOU TURN IT OFF AND RE-START IT. THIS CAN BE EXTREMELY DANGEROUS IF IT HAPPENS AT A POINT WHERE IT'S HARD TO PULL OVER. AFTER READING MESSAGE BOARDS, IT SEEMS TO BE A FAIRLY COMMON PROBLEM IN 2005 EXPEDITIONS. *TR
NHTSA ODI #10260501
70,000 miles · Mar 2, 2009
Fuel System, Other
2005 FORD EXPEDITION - NORMAL DRIVING, COMPLETE LOSS OF DRIVE POWER. COMES UP AS ELECTRONIC THROTTLE. YOU MUST PULL OFF ROAD, TURN VEHICLE OFF, THEN RESTART. THIS IS VERY WIDESPREAD, JUST DO A GOOGLE SEARCH FOR THROTTLE EXPEDITION. IT HAS RECURRED AT VARIOUS TIMES ALWAYS SEEMING TO RESET. FORD WANT $700 TO FIX. *TR
NHTSA ODI #10260491
68,000 miles · Feb 23, 2009
Engine And Engine Cooling
TL*THE CONTACT OWNS A 2005 FORD EXPEDITION. WHILE DRIVING 50 MPH, THE VEHICLE BEGAN TO FAIL AND THE CONTACT NOTICED THAT HER SPEED REDUCED TO 30 MPH. SHE WAS ABLE TO APPLY THE BRAKES AND SLOW THE VEHICLE DOWN. THE VEHICLE THEN SHUT OFF AND TOOK THREE ATTEMPTS TO RESTART. THE DEALER DETERMINED THAT THE THROTTLE BODY DISENGAGE…
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TL*THE CONTACT OWNS A 2005 FORD EXPEDITION. WHILE DRIVING 50 MPH, THE VEHICLE BEGAN TO FAIL AND THE CONTACT NOTICED THAT HER SPEED REDUCED TO 30 MPH. SHE WAS ABLE TO APPLY THE BRAKES AND SLOW THE VEHICLE DOWN. THE VEHICLE THEN SHUT OFF AND TOOK THREE ATTEMPTS TO RESTART. THE DEALER DETERMINED THAT THE THROTTLE BODY DISENGAGED AND THE VEHICLE WAS REPAIRED AT THE COST OF $700. THE CONTACT IS IN THE PROCESS OF NOTIFYING THE MANUFACTURER. THE VIN WAS UNAVAILABLE. THE FAILURE MILEAGE WAS 68,000.
NHTSA ODI #10259697
42,900 miles · Feb 11, 2009
Engine And Engine Cooling
I HAVE A 2005 FORD EXPEDITION WITH 42K MILES AND I WAS GOING 30 MPH WHEN I LOST THE GAS PEDAL(POWER) TO MY VEHICLE. WARNING LIGHT CAME ON AND THEN I PULLED TO SIDE OF ROAD. LUCKY I WAS NOT HIT FROM BEHIND DUE TO LOSING POWER TO THE ENGINE. TURNED VEHICLE OFF FOR A FEW MINUTES AND THEN TURNED BACK ON. NO WARNING LIGHT AND TRUCK R…
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I HAVE A 2005 FORD EXPEDITION WITH 42K MILES AND I WAS GOING 30 MPH WHEN I LOST THE GAS PEDAL(POWER) TO MY VEHICLE. WARNING LIGHT CAME ON AND THEN I PULLED TO SIDE OF ROAD. LUCKY I WAS NOT HIT FROM BEHIND DUE TO LOSING POWER TO THE ENGINE. TURNED VEHICLE OFF FOR A FEW MINUTES AND THEN TURNED BACK ON. NO WARNING LIGHT AND TRUCK RAN FINE. TOOK IT TO LOCAL APPLE FORD DEALER WHO FOR $98 TELLS ME I NEED TO SPEND ANOTHER $600 TO REPLACE ELECTRONIC THROTTLE BODY. II HAVE NOTICED FROM VARIOUS INTERNET SITES THAT THIS IS A VERY COMMON PROBLEM WITH THIS VEHICLE AND THAT IT CAN HAPPEN AT ANY TIME. AFTER A LONG DISCUSSION WITH SERVICE MANAGER I DECIDED TO DECLINE THE REPAIR UNTIL I CONTACT FORD AND NATIONAL HIGHWAY SAFETY BOARD. SO FAR, THE TRUCK IS STILL RUNNING FINE, BUT I EXPECT IT IS GOING TO DO THE SAME THING AGAIN. THIS IS SOMETHING FORD AND/OR THE FEDERAL GOV.'T SHOULD RECALL BEFORE SOMEONE GETS KILLED. *TR
NHTSA ODI #10258393
62,000 miles · Feb 9, 2009
Electrical System
I WAS DRIVING ON THE FREEWAY AT 65MPH AND THE "CHECK ELECTRONIC THROTTLE CONTROL" LIGHT CAME ON AND THEN MY VEHICLE ENGINE SHUT OFF. I HAD TO PULL OVER WITH NO POWER AND LITTLE ABILITY TO TURN BEFORE VEHICLE WOULD RESTART. IT HAS DONE THIS NOW THREE TIMES. I HAVE RESEARCHED THE COST FOR REPAIRS BUT DUE TO THE HIGH EXPENSE ($5…
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I WAS DRIVING ON THE FREEWAY AT 65MPH AND THE "CHECK ELECTRONIC THROTTLE CONTROL" LIGHT CAME ON AND THEN MY VEHICLE ENGINE SHUT OFF. I HAD TO PULL OVER WITH NO POWER AND LITTLE ABILITY TO TURN BEFORE VEHICLE WOULD RESTART. IT HAS DONE THIS NOW THREE TIMES. I HAVE RESEARCHED THE COST FOR REPAIRS BUT DUE TO THE HIGH EXPENSE ($500) I AM NOT ABLE AT THIS TIME TO FIX. *TR
NHTSA ODI #10258037
32,291 miles · Feb 8, 2009
Fuel System, GasolineFire
ON 1/23 MY WIFE (5 MONTHS PREGNANT) WAS DRIVING ALONE WITH MY 2 YEAR OLD SON THROUGH THE CA DESERT ON HER WAY TO PHOENIX, AZ. IN OUR 2005 FORD EXPEDITION WITH ONLY 35K MILES ON IT. ABOUT 20 MILES FROM BLYTHE, CA THREE FUEL INJECTORS FAILED. LUCKILY SHE FOUND A FORD DEALERSHIP IN BLYTHE THAT WAS OPEN ON THAT FRIDAY AND ABLE TO RE…
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ON 1/23 MY WIFE (5 MONTHS PREGNANT) WAS DRIVING ALONE WITH MY 2 YEAR OLD SON THROUGH THE CA DESERT ON HER WAY TO PHOENIX, AZ. IN OUR 2005 FORD EXPEDITION WITH ONLY 35K MILES ON IT. ABOUT 20 MILES FROM BLYTHE, CA THREE FUEL INJECTORS FAILED. LUCKILY SHE FOUND A FORD DEALERSHIP IN BLYTHE THAT WAS OPEN ON THAT FRIDAY AND ABLE TO REPLACE THEM. UPON ARRIVAL IN PHOENIX, ANOTHER DEALER DETERMINED THAT THE CATALYTIC CONVERTER WAS DESTROYED AS A RESULT. I WOULD LIKE FORD TO REPLACE THE REMAINING 5 FUEL INJECTORS BEFORE THEY FAIL. WHAT KIND OF FORD POLICY IS IT TO EXTEND THE WARRANTY TO 120K MILES ON A KNOWN DEFECT AND WAIT FOR DISASTER? IT IS INSANE TO NOT BE ABLE TO RELY ON OUR CAR FOR LONG DISTANCE TRAVEL AND ALWAYS WORRY ABOUT THIS INCIDENT REPEATING. THE COST OF REPLACING THE CATALYTIC CONVERTER AND RESULTING POLLUTION SHOULD ALSO BE A CONSIDERATION TO FORD? FYI: THE INJECTORS FROZE IN THE OPEN POSITION AND FLOODED THE ENGINE AND EXHAUST SYSTEM WITH FUEL I.E. FIRE! *TR
NHTSA ODI #10257972
75,000 miles · Feb 5, 2009
Electrical System
I WAS DRIVING ABOUT 70MPH WHEN THE MESSAGE CENTER TONE SOUNDED AND THE MESSAGE READ "CHECK THROTTLE CONTROL". THE ENGINE CONTINUED TO RUN, HOWEVER, THE ACCELERATOR BECAME INOPERABLE. IT SEEMS AS IF A LOT OF 05 EXPEDITION OWNERS ARE HAVING THE SAME PROBLEM. THIS IS JUST WAY TO DANGEROUS TO DRIVE WITH THIS ISSUE. I NEVER DRIVE IN…
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I WAS DRIVING ABOUT 70MPH WHEN THE MESSAGE CENTER TONE SOUNDED AND THE MESSAGE READ "CHECK THROTTLE CONTROL". THE ENGINE CONTINUED TO RUN, HOWEVER, THE ACCELERATOR BECAME INOPERABLE. IT SEEMS AS IF A LOT OF 05 EXPEDITION OWNERS ARE HAVING THE SAME PROBLEM. THIS IS JUST WAY TO DANGEROUS TO DRIVE WITH THIS ISSUE. I NEVER DRIVE IN THE MIDDLE LANE ON HIGHWAYS NOW FOR FEAR THAT THIS COULD HAPPEN AT ANY TIME. *TR
NHTSA ODI #10257553
85,000 miles · Feb 1, 2009
Electrical System
WHILE DRIVING THE VEHICLE WILL HAVE NOT HAVE ANY THROTTLE RESPONSE AND "CHECK ELECTRONIC THROTTLE COMPONENT" SHOWS ON DASH. AFTER PULLING TO THE SIDE OF THE ROAD, OR COASTING INTO SOMEONE'S DRIVE-WAY ON A CURVEY ROAD, TURN THE IGNITION OFF AND SIT FOR A FEW MINUTES AND RESTART ENGINE AND IS FINE. HAS OCCURRED 3 TIMES NOW, ALL 3 …
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WHILE DRIVING THE VEHICLE WILL HAVE NOT HAVE ANY THROTTLE RESPONSE AND "CHECK ELECTRONIC THROTTLE COMPONENT" SHOWS ON DASH. AFTER PULLING TO THE SIDE OF THE ROAD, OR COASTING INTO SOMEONE'S DRIVE-WAY ON A CURVEY ROAD, TURN THE IGNITION OFF AND SIT FOR A FEW MINUTES AND RESTART ENGINE AND IS FINE. HAS OCCURRED 3 TIMES NOW, ALL 3 AT SPEEDS LESS THAN 45 MPH. TOOK THE VEHICLE TO FORD DEALERSHIP WHERE THEY CHARGED ME $75 TO TELL ME THE BATTERY NEEDED TO BE REPLACED BECAUSE THAT IS ALL THE CODES THAT THEY CAME UP WITH. THEN I WOULD HAVE TO RETURN THE VEHICLE TO HAVE IT CHECKED AGAIN. ON MY DESCRIPTION OF SERVICE CODES P-1867-2F, B-1317-2F, B1318-2F, B2477-60, B2486-20, B1318-20, U1900-20, P0121-FF, P2104-FF, P2112FF, B1318FF, WERE ALL FOUND. *TR
NHTSA ODI #10257081
62,000 miles · Jan 24, 2009
Engine And Engine Cooling
2005 FORD EXPEDITION EDDIE BAUER. DURING VEHICLE OPERATION THE ENGINE SUDDENLY DIES AND A "CHECK ELECTRONIC FUEL CONTROL" MESSAGE COMES UP ON THE DISPLAY. THIS IS EXTREMELY DANGEROUS AS IT OCCURS WHILE DRIVING ON THE HIGHWAY. AFTER THE VEHICLE IS PULLED OVER AND IGNITION IS TURNED OFF THE VEHICLE WILL RESTART. THIS HAS OCCUR…
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2005 FORD EXPEDITION EDDIE BAUER. DURING VEHICLE OPERATION THE ENGINE SUDDENLY DIES AND A "CHECK ELECTRONIC FUEL CONTROL" MESSAGE COMES UP ON THE DISPLAY. THIS IS EXTREMELY DANGEROUS AS IT OCCURS WHILE DRIVING ON THE HIGHWAY. AFTER THE VEHICLE IS PULLED OVER AND IGNITION IS TURNED OFF THE VEHICLE WILL RESTART. THIS HAS OCCURRED MULTIPLE TIMES IN MY VEHICLE. AFTER DOING NUMEROUS INTERNET SEARCHES THIS SEEMS TO BE A RECURRING PROBLEM IN MULTIPLE 2005 EXPEDITIONS. *TR
NHTSA ODI #10256194
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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