IllustrationELECTRONIC THROTTLE CONTROL LIGHT, I WAS DRIVING ABOUT 50MPH WHEN THE CAR SLOWED DOWN TO A STOP AND THE GAS PEDAL WOULD NOT WORK. THE CAR WAS RUNNING AND ROLLING, BUT I COULD NOT ACCELERATE. (SCARY) *TR
2005 Ford Expedition
Owner reports · Recalls · Investigations
More warning signs than most Expedition years
Owner complaints for the 2005 Ford Expedition are substantially higher than the model-year median of 155.
About this comparison →How this year compares
Owner complaints by model year
Compare all Expedition years →Counts vary with age, sales and reporting. They are not failure rates.
What owners reported most
All reported categories
Tap a category to read its complaints. One report may name several components.
When problems were reported
Mileage at the reported incident
250–25K
4025–50K
7950–75K
6275–100K
60100–150K
23150K+
289 reports with mileage · 26 unknown
NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.
What to inspect
Issues worth paying extra attention to based on owner reports.
- Electrical System. Review the 76 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Vehicle Speed Control. Review the 66 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Engine. Review the 57 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
NHTSA owner reports · September 18, 2026 snapshot.
20 crash reports6 fire reports10 injury reports
What owners actually said
315 reportsTL*THE CONTACT OWNS A 2005 FORD EXPEDITION. THE VEHICLE WAS PURCHASED BRAND NEW FROM THE DEALER AND UNDERWENT REGULARLY SCHEDULED MAINTENANCE AT THE SAME DEALER. AT 94,000 MILES, THE ENGINE FAILED. WHENEVER THE VEHICLE REACHED ABOVE 30 MPH, THE VEHICLE WOULD LUNGE FORWARD AND FAIL TO DRIVE SMOOTHLY. THE FAILURE OCCURRED ONLY…
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TL*THE CONTACT OWNS A 2005 FORD EXPEDITION. THE VEHICLE WAS PURCHASED BRAND NEW FROM THE DEALER AND UNDERWENT REGULARLY SCHEDULED MAINTENANCE AT THE SAME DEALER. AT 94,000 MILES, THE ENGINE FAILED. WHENEVER THE VEHICLE REACHED ABOVE 30 MPH, THE VEHICLE WOULD LUNGE FORWARD AND FAIL TO DRIVE SMOOTHLY. THE FAILURE OCCURRED ONLY ONCE AND THE DEALER WAS UNABLE TO DETERMINE THE CAUSE OF THE FAILURE. THE DEALER HAD TO TEAR APART THE ENGINE IN ORDER TO LOCATE THE FAILURE. AFTER INSPECTION, THE DEALER STATED THAT THE TIMING CHAIN TENSIONER NEEDED TO BE REPLACED. THE FAILURE WAS CORRECTED AFTER THE TIMING CHAIN WAS REPLACED. THE CONTACT STATED THAT THE ISSUE SHOULD NOT HAVE OCCURRED TO A VEHICLE WITH 90,000 MILES AND LESS THAN FOUR YEARS OLD. THE CONTACT PAID FOR ALL THE REPAIRS. THE FAILURE MILEAGE WAS 94,746 AND CURRENT MILEAGE WAS 94,900. UPDATED 02/05/09. *LJ UPDATED 02/10/09. *JB
WHEN I TURNED THE ENGINE ON AND PUT CAR ON REVERSE IT SPEED OUT OF CONTROL, IMMEDIATELY TRY TO PUSH ON BRAKES BUT IT DIDN'T STOP AND I CRASHED INTO A PALM TREE. *TR
"CHECK ELECTRONIC THROTTLE" MESSAGE APPEARED AND ACCELERATOR PEDAL BECAME INOPERATIVE. THIS IS THE SECOND TIME THIS HAS OCCURRED. SHIFTED VEHICLE INTO NEUTRAL, RESTARTED ENGINE WHILE ROLLING ALONG AND ERROR WAS CORRECTED. *TR
"CHECK ELECTRONIC THROTTLE" MESSAGE APPEARED AND ACCELERATOR PEDAL BECAME UNRESPONSIVE IN TRAFFIC. PULLED OVER, RESTARTED ENGINE AND ISSUE CORRECTED ITSELF. *TR
2005 FORD EXPEDITION CAR FIRE LOST NINE MONTHS OF PAYMENTS CARS SEATS WALLET EASY UP CANOPIES ETC. *TR
I WAS DRIVING 60MPH DOWN THE HIGHWAY AND THE DASH LIT UP WITH "CHECK ELECTRONIC FUEL CONTROL." I WAS ABLE TO GET THE VEHICLE TO THE SIDE OF THE ROAD AS THE ENGINE TURNED ITSELF OFF, NO POWER STEERING, AND LIMITED BRAKING ABILITY. AFTER A FEW MINUTES IT RESTARTED AND I WAS ABLE TO LIMP IT BACK HOME AND I PLAN ON TAKING INTO THE…
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I WAS DRIVING 60MPH DOWN THE HIGHWAY AND THE DASH LIT UP WITH "CHECK ELECTRONIC FUEL CONTROL." I WAS ABLE TO GET THE VEHICLE TO THE SIDE OF THE ROAD AS THE ENGINE TURNED ITSELF OFF, NO POWER STEERING, AND LIMITED BRAKING ABILITY. AFTER A FEW MINUTES IT RESTARTED AND I WAS ABLE TO LIMP IT BACK HOME AND I PLAN ON TAKING INTO THE LOCAL FORD DEALERSHIP IN THE MORNING. *TR
I BOUGHT MY 2005 FORD EXPEDITION IN MARCH 2007 WITH 21K MILES ON IT. I HAVE HAD TO REPLACE 2 DIFFERENT INJECTORS IN 16 MONTHS BECAUSE THE VEHICLE WILL START CUTTING BACK AND ACTING LIKE IT WANTS TO CUT OFF WHEN IT STOPS AT A LIGHT . THE MOST RECENT REPLACEMENT CAME WHEN I DROVE IT 5 MILES FROM HOME AND IT JERKED CONTINUOUSLY T…
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I BOUGHT MY 2005 FORD EXPEDITION IN MARCH 2007 WITH 21K MILES ON IT. I HAVE HAD TO REPLACE 2 DIFFERENT INJECTORS IN 16 MONTHS BECAUSE THE VEHICLE WILL START CUTTING BACK AND ACTING LIKE IT WANTS TO CUT OFF WHEN IT STOPS AT A LIGHT . THE MOST RECENT REPLACEMENT CAME WHEN I DROVE IT 5 MILES FROM HOME AND IT JERKED CONTINUOUSLY THE ENTIRE INSIDE OF THE VEHICLE SMELLED LIKE GAS VERY STRONGLY AS WELL AS THE EXHAUST. THE TRUCK STAYS PARKED MOST OF THE TIME BECAUSE IM TOO SCARED TO DRIVE IT AND ITS A GAS HOG!!!!!! THE REPLACEMENT OF THE INJECTORS ARE NOT CHEAP!!!! THE INSIDE LIGHTS WILL COME ON AND GO OFF AT ANYTIME FOR NO REASON. I TAP THE BRAKES AND THEY COME ON, I ROLL THE WINDOW UP OR DOWN AND THEY COME ON. I HAVE ALSO HAD TO REPLACE THE BATTERY DUE TO THIS HAPPENING EVEN WHEN THE TRUCK HAS BEEN PARKED FOR HOURS. I HAVE REPLACED THE OXYGEN SENSOR AND A COLI PACK. ITS NEVER ENDING AND I FEEL LIKE I SHOULD NOT HAVE TO CONTINUE TO REPLACE THESE THINGS WHEN I AM OBVIOUSLY NOT THE ONLY ONE WITH THIS PROBLEM. FORD NEEDS TO STEP UP AND TAKE RESPONSIBILITY FOR THEIR CRAPPY PRODUCTS. I HAVE 5 MORE YEARS @ $515 PER MONTH TO PAY FOR THIS PIECE OF CRAP!!!!!!!!!!!! *TR
MY WIFE WAS DRIVING OUR 2005 FORD EXPEDITION WITH 50,000 MILES. SHE STATED THAT THE RADIO QUIT WORKING AND THEN THE VEHICLE QUIT RUNNING. AT THAT POINT THE HORN BEGAN TO BLOW CONTINUOUSLY UNTIL SMOKE STARTED TO COME OUT OF THE RIGHT SIDE OF THE DASH. AT THIS TIME SHE EXITED THE VEHICLE WITH OUR BOYS AND CALLED THE FIRE DEPT. BY …
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MY WIFE WAS DRIVING OUR 2005 FORD EXPEDITION WITH 50,000 MILES. SHE STATED THAT THE RADIO QUIT WORKING AND THEN THE VEHICLE QUIT RUNNING. AT THAT POINT THE HORN BEGAN TO BLOW CONTINUOUSLY UNTIL SMOKE STARTED TO COME OUT OF THE RIGHT SIDE OF THE DASH. AT THIS TIME SHE EXITED THE VEHICLE WITH OUR BOYS AND CALLED THE FIRE DEPT. BY THE TIME THEY ARRIVED THE VEHICLE WAS FULLY INVOLVED WITH FIRE. NEEDLESS TO SAY THE EXPEDITION IS TOTALED FROM THE FIRE. THE ENTIRE INTERIOR IS BURNT UP AND MELTED. I HAVE FOUND SIMILAR COMPLAINTS ON SEVERAL FORUMS. *TR
2005 FORD EXPEDITION 4 WHEEL DRIVE, VEHICLE FACTORY RIMS SPLITTING APART, OUTWARD SIDE OF RIM. RIMS ARE COMING APART ALMOST FULL CIRCUMFERENCE OF RIM INSIDE OF RIM. CANNOT BE SEEN FROM OUTSIDE. HAS HAPPENED TO SEVERAL VEHICLES. ALSO HAVE LOCAL REPORTS FROM LOCAL GOVERNMENT AGENCIES OF SAME PROBLEM. FEEL IT IS AND EXTREME SAFETY …
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2005 FORD EXPEDITION 4 WHEEL DRIVE, VEHICLE FACTORY RIMS SPLITTING APART, OUTWARD SIDE OF RIM. RIMS ARE COMING APART ALMOST FULL CIRCUMFERENCE OF RIM INSIDE OF RIM. CANNOT BE SEEN FROM OUTSIDE. HAS HAPPENED TO SEVERAL VEHICLES. ALSO HAVE LOCAL REPORTS FROM LOCAL GOVERNMENT AGENCIES OF SAME PROBLEM. FEEL IT IS AND EXTREME SAFETY ISSUE. HAVE REPLACED RIMS WITH FACTORY RIMS. HAVE KEPT OLD RIMS TO VIEW. *TR
Official recalls
0No recalls in this snapshot.
Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗
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