NHTSA owner reports · September 18, 2026 snapshot.
What owners actually said
315 reports16,000 miles · Jun 26, 2008
Engine And Engine CoolingPower Train
TL*THE CONTACT OWNS A 2005 FORD EXPEDITION. THE CONTACT STATED THAT THE VEHICLE STALLS AND CONSTANTLY SHUTS OFF AT VARIOUS SPEEDS. THE VEHICLE WAS TAKEN TO THE DEALER ON EIGHT OCCASIONS FOR THE FAILURES. IN JANUARY OF 2008, THE DIAGNOSTIC INDICATED THAT THE THROTTLE BODY WAS THE CAUSE OF THE FAILURE AND IT WAS REPLACED. THE …
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TL*THE CONTACT OWNS A 2005 FORD EXPEDITION. THE CONTACT STATED THAT THE VEHICLE STALLS AND CONSTANTLY SHUTS OFF AT VARIOUS SPEEDS. THE VEHICLE WAS TAKEN TO THE DEALER ON EIGHT OCCASIONS FOR THE FAILURES. IN JANUARY OF 2008, THE DIAGNOSTIC INDICATED THAT THE THROTTLE BODY WAS THE CAUSE OF THE FAILURE AND IT WAS REPLACED. THE MOST RECENT FAILURE OCCURRED ON JUNE 1, 2008 WHILE DRIVING 60 MPH. THE VEHICLE WAS TOWED TO THE DEALER AND THEY STATED THAT THE TRANSMISSION FAILED. THE DEALER REPLACED THE TRANSMISSION. THE CONTACT SPENT $2,400 TO REPAIR THE VEHICLE THAT WAS PURCHASED NEW IN 2005. THE FAILURE MILEAGE WAS 16,000 AND CURRENT MILEAGE WAS 39,000.
NHTSA ODI #10232367
43,000 miles · Jun 24, 2008
Structure
FORD EXPEDITION PAINT. I PURCHASED A NEW 2005 FORD EXPEDITION EDDIE BAUER EDITION IN 5/2005 FROM A CAR DEALER. THE 36000/3 YEAR WARRANTY HAS EXPIRED AND THE PAINT IS BLISTERING ON THE TAILGATE. I CALLED DEALER AND THEY SAID IT IS A MANUFACTURING DEFECT AND THEY WILL NOT PAY FOR IT BUT IT WILL DO NO GOOD TO FIX IT UNLESS THE E…
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FORD EXPEDITION PAINT. I PURCHASED A NEW 2005 FORD EXPEDITION EDDIE BAUER EDITION IN 5/2005 FROM A CAR DEALER. THE 36000/3 YEAR WARRANTY HAS EXPIRED AND THE PAINT IS BLISTERING ON THE TAILGATE. I CALLED DEALER AND THEY SAID IT IS A MANUFACTURING DEFECT AND THEY WILL NOT PAY FOR IT BUT IT WILL DO NO GOOD TO FIX IT UNLESS THE ENTIRE TAILGATE IS REPLACED WITH STEEL. THERE IS A SERVICE BULLETIN OUT ON THIS ISSUE AND THEY ARE NOT STANDING BEHIND IT. *TR
NHTSA ODI #10232174
17,275 miles · May 16, 2008
Power Train
TL*THE CONTACT OWNS A 2005 FORD EXPEDITION. WHEN THE CONTACT STARTS THE VEHICLE, THE RPM'S INCREASED TO OVER 5,000 WHILE IT WAS IN GEAR AND WITH THE BRAKE PEDAL DEPRESSED. WHEN THE VEHICLE WAS PLACED INTO NEUTRAL, THE FAILURE CEASED AND THE VEHICLE DROVE NORMALLY. THE FAILURE WAS INTERMITTENT AND THE CONTACT HAS NOT BEEN IN A…
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TL*THE CONTACT OWNS A 2005 FORD EXPEDITION. WHEN THE CONTACT STARTS THE VEHICLE, THE RPM'S INCREASED TO OVER 5,000 WHILE IT WAS IN GEAR AND WITH THE BRAKE PEDAL DEPRESSED. WHEN THE VEHICLE WAS PLACED INTO NEUTRAL, THE FAILURE CEASED AND THE VEHICLE DROVE NORMALLY. THE FAILURE WAS INTERMITTENT AND THE CONTACT HAS NOT BEEN IN ANY CRASHES. THE VEHICLE HAS BEEN DIAGNOSED BY THE DEALER SEVERAL TIMES, BUT THE FAILURE CONTINUES. THE CURRENT MILEAGE WAS 33,000 AND FAILURE MILEAGE WAS 17,275.
NHTSA ODI #10227989
53,092 miles · May 14, 2008
Service Brakes, HydraulicCrash
SLOW SPEED, APPLIED BRAKES, NO RESPONSE. PEDAL WAS SOFT. *TR
NHTSA ODI #10227821
44,125 miles · May 8, 2008
Fuel System, Gasoline
OUR 2005 FORD EXPEDITION EDDIE BAUER WAS DRIVING EXTREMELY ROUGH, WAS DIFFICULT TO START, AND THERE WAS ALSO A STRONG SMELL OF FUEL IN THE CABIN. WE WERE ABLE TO MAKE IT TO THE NEAREST LOCAL FORD DEALERSHIP. THEY INSPECTED THE VEHICLE AND INFORMED US THAT TWO OF OUR FUEL INJECTORS HAD GONE BAD, WHICH HAD ALSO DAMAGED TWO SPARK …
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OUR 2005 FORD EXPEDITION EDDIE BAUER WAS DRIVING EXTREMELY ROUGH, WAS DIFFICULT TO START, AND THERE WAS ALSO A STRONG SMELL OF FUEL IN THE CABIN. WE WERE ABLE TO MAKE IT TO THE NEAREST LOCAL FORD DEALERSHIP. THEY INSPECTED THE VEHICLE AND INFORMED US THAT TWO OF OUR FUEL INJECTORS HAD GONE BAD, WHICH HAD ALSO DAMAGED TWO SPARK PLUGS. APPARENTLY THEY FROZE OPEN AND ALLOWED TOO MUCH FUEL INTO THE SYSTEM. SINCE FORD IS AWARE OF THIS PROBLEM THEY HAVE EXTENDED THE WARRANTY TO VEHICLE OWNERS FOR THE DEFECTIVE FUEL INJECTORS TO 120,000 MILES. LATE LAST YEAR THEY SENT OUT A LETTER TO IMPACTED VEHICLE OWNERS. HOWEVER, THEY ONLY REPLACE THE FUEL INJECTORS AS THEY GO BAD. WE NOW HAVE TWO NEW AND IMPROVED FUEL INJECTORS IN OUR VEHICLE AND SIX OF THE FAULTY ONES. WE ARE CONCERNED WITH THE SAFETY OF US CONTINUING TO DRIVE THIS VEHICLE. THE ENGINE COULD STOP AT ANY MOMENT LEAVING US IN A DANGEROUS SITUATION IN TRAFFIC OR IN A REMOTE AREA, AND WITH THE FLOODING OF FUEL INTO THE SYSTEM THERE IS AN INCREASED RISK OF FIRE. THERE SHOULD BE A RECALL ON THESE FAULTY FUEL INJECTORS FOR THE SAFETY OF THE VEHICLE OWNERS. I'M DISAPPOINTED THAT FORD HAS CHOSEN TO NOT STAND BY THEIR PRODUCT AND LEAVE THEIR CUSTOMER IN A POTENTIALLY DANGEROUS SITUATION. OTHERWISE, WE HAVE BEEN PLEASED WITH THIS VEHICLE. I RECOMMEND THAT THE NHTSA INVESTIGATE THIS ISSUE. THERE ARE BLOGS ONLINE WHERE OTHERS HAVE EXPERIENCED SIMILAR UNSAFE SITUATIONS RELATING TO THESE FAULTY FUEL INJECTORS. MANY HAVE HAD TO GO BACK TO FORD MULTIPLE TIMES ALREADY, AS AN INJECTOR GOES BAD. THIS SITUATION COULD BE REMEDIED IF FORD WOULD RECALL AND REPLACE ALL OF THESE INJECTORS WHETHER THEY HAVE FAILED YET OR NOT. *TR
NHTSA ODI #10227101
Mileage unknown · Apr 13, 2008
Engine And Engine Cooling
RECURRING ENGINE NOISE WHICH IS MORE NOTICEABLE DURING COLD WEATHER. UNDER LOAD THE ENGINE , PARTICULARLY AT 2000 RPM, SOUNDS LIKE THERE IS A MANIFOLD LEAK OR A VALVE TICKING. I HAVE BEEN TO MY DEALER TWICE(OUT OF BUSINESS) AND TWO OTHER DEALERS THREE TIMES WITH NO SATISFACTORY RESULTS. *TR
NHTSA ODI #10224328
42,196 miles · Apr 2, 2008
Visibility
MOONROOF IS LEAKING CAUSING INTERIOR WATER DAMAGE. *TR
NHTSA ODI #10223199
75,000 miles · Mar 6, 2008
Air BagsCrashInjury
TL*THE CONTACT OWNS A 2005 FORD EXPEDITION. WHILE DRIVING ON A WET ROAD AT 45 MPH, THE BACK OF THE VEHICLE BEGAN TO SLIDE. THE CONTACT WAS HIT BY ANOTHER VEHICLE AND SPUN OUT OF CONTROL ACROSS FOUR LANES OF TRAFFIC. THE BACK END OF THE VEHICLE CRASHED INTO A CEMENT BARRACADE. A VEHICLE THAT WAS ENTERING THE HIGHWAY CRASHED INTO…
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TL*THE CONTACT OWNS A 2005 FORD EXPEDITION. WHILE DRIVING ON A WET ROAD AT 45 MPH, THE BACK OF THE VEHICLE BEGAN TO SLIDE. THE CONTACT WAS HIT BY ANOTHER VEHICLE AND SPUN OUT OF CONTROL ACROSS FOUR LANES OF TRAFFIC. THE BACK END OF THE VEHICLE CRASHED INTO A CEMENT BARRACADE. A VEHICLE THAT WAS ENTERING THE HIGHWAY CRASHED INTO THE DRIVERS SIDE. THE AIR BAGS NEVER DEPLOYED. THE AMBULANCE AND POLICE ARRIVED AND TRANSPORTED THE CONTACT TO THE HOSPITAL. THE VEHICLE WAS DESTROYED. THE MANUFACTURER WAS NOTIFIED, THE CONTACT HAS BEEN UNSUCCESSFUL AT SPEAKING WITH THEM. THE CURRENT AND FAILURE MILEAGE WAS 75,000.
NHTSA ODI #10220279
85,000 miles · Mar 6, 2008
Electrical System
I WAS DRIVING MY 2005 FORD EXPEDITION, 85,000 MILE DRIVEN, WAS TRAVELING ON LEVEL GROUND IN TRAFFIC AT 45 MPH WHEN THE ENGINE SPEED WENT TO IDLE AND I COULD NOT ACCELERATE. THE ENGINE WAS STILL RUNNING AND BOTH POWER BRAKES AND POWER STEERING STILL FUNCTIONED. THE MESSAGE ON THE INFORMATION PANEL STATED SOMETHING TO THE EFFECT…
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I WAS DRIVING MY 2005 FORD EXPEDITION, 85,000 MILE DRIVEN, WAS TRAVELING ON LEVEL GROUND IN TRAFFIC AT 45 MPH WHEN THE ENGINE SPEED WENT TO IDLE AND I COULD NOT ACCELERATE. THE ENGINE WAS STILL RUNNING AND BOTH POWER BRAKES AND POWER STEERING STILL FUNCTIONED. THE MESSAGE ON THE INFORMATION PANEL STATED SOMETHING TO THE EFFECT OF "ELECTRONIC THROTTLE DYSFUNCTION." FORTUNATELY, I WAS NOT IN HEAVY TRAFFIC AND IN THE RIGHT HAND LANE AND WAS ABLE TO COAST TO A STOP ON THE SIDE OF THE ROAD. THE IGNITION WAS TURNED OFF AND ALLOWED TO SET FOR A FEW MOMENTS. UPON RESTARTING EVERYTHING FUNCTIONED PROPERLY AND HAS CONTINUED TO DO SO SINCE. THIS COULD HAVE EASILY BEEN A FATAL PROBLEM IF THE TIMING HAD BEEN POOR. MY FORD DEALER SERVICE MANAGER STATED THIS IS THE 3RD. ONE LIKE THIS IN THE LAST TWO WEEKS. MY VEHICLE IS PRESENTLY BEING REPAIRED BY REPLACING PART OF ITS COMPUTER. UNFORTUNATELY, FORD DOES NOT SEE FIT TO ASSUME RESPONSIBILITY. *TR
NHTSA ODI #10220261
56,981 miles · Feb 25, 2008
Fuel System, Gasoline
IT TAKES 20 MINUTES TO FILL UP MY GAS TANK. FORD PUT SOME TIME OF RESTRICTION OR REROUTED THE FUMES AT THE GAS CAP. I HAVE TO ACTUALLY HOLD THE NOZZLE BACK AND INCH FROM THE OPENING AND SHOOT THE GAS AT THE TANK. THIS IS A VERY DANGEROUS SITUATION AND I AM SURE MUCH MORE DANGEROUS THAN THE ORIGINAL PROBLEM THE ENGINEERS WERE …
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IT TAKES 20 MINUTES TO FILL UP MY GAS TANK. FORD PUT SOME TIME OF RESTRICTION OR REROUTED THE FUMES AT THE GAS CAP. I HAVE TO ACTUALLY HOLD THE NOZZLE BACK AND INCH FROM THE OPENING AND SHOOT THE GAS AT THE TANK. THIS IS A VERY DANGEROUS SITUATION AND I AM SURE MUCH MORE DANGEROUS THAN THE ORIGINAL PROBLEM THE ENGINEERS WERE TRYING TO CORRECT (DUE TO A LAWSUIT). NOW FORD IS SAYING THAT THEY WILL NEED TO PUT THE CAR ON AN ENGINE ANALYZER ($160) THEN LOWER THE GAS TANK ($500 TO $600) IN ORDER TO SEE IF THE FUME VAPOR HOSE MAY BE FROZEN OR SUPPOSEDLY THERE IS A REPLACEABLE FILTER THAT THEY LOCATED ABOVE THE FUEL TANK. MY RESPONSE WAS ..."NO ENGINEER WOULD LOCATE A REPLACEABLE FILTER ABOVE THE FUEL TANK"! THEN THE SERVICE MANAGER BLAMED THE PROBLEM ON EPA...AS HE IS AWARE OF OTHER EXPEDITIONS WITH THIS PROBLEM...I SAID " I RETIRED FROM EPA..THEY MAY HAVE REQUIRED YOU TO DO SOMETHING WITH THE EMISSIONS....BUT THEY NEVER INSTRUCTED YOUR ENGINEERS TO LOCATE A FILTER ABOVE THE FUEL TANK"!!! I HAVE SPOKE WITH TWO DIFFERENT FORD GARAGES AND FILL THAT THEY ARE GIVING ME A RUN AROUND...MAYBE BECAUSE I AM A WOMEN AND THEY THINK I WILL PAY CLOSE TO $1,000 TO JUST GET FUEL IN THE VEHICLE! *TR
NHTSA ODI #10219128
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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