NHTSA owner reports · September 18, 2026 snapshot.
What owners actually said
315 reports60,000 miles · Feb 25, 2008
Fuel System, Gasoline
TL*THE CONTACT OWNS A 2005 FORD EXPEDITION. THE CONTACT CANNOT INSERTED THE NOZZLE INTO THE FUEL TANK TO PLACE GAS IN THE VEHICLE ,BUT THE GAS BLEW BACK OUT AT HIM AND HE STATED THAT IT TOOK 25 MINUTES TO FILL UP THE VEHICLE. FORD STATED THAT THE REPAIR WOULD COST AT LEAST $500. THE DEALER WOULD HAVE TO REMOVE AND REINSTALL …
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TL*THE CONTACT OWNS A 2005 FORD EXPEDITION. THE CONTACT CANNOT INSERTED THE NOZZLE INTO THE FUEL TANK TO PLACE GAS IN THE VEHICLE ,BUT THE GAS BLEW BACK OUT AT HIM AND HE STATED THAT IT TOOK 25 MINUTES TO FILL UP THE VEHICLE. FORD STATED THAT THE REPAIR WOULD COST AT LEAST $500. THE DEALER WOULD HAVE TO REMOVE AND REINSTALL THE FUEL TANK. THE MANUFACTURER STATED THAT NOTHING COULD BE DONE AND ADVISED THE CONTACT TO CALL NHTSA AND FILE A COMPLAINT. THE CURRENT AND FAILURE MILEAGES WERE 60,000. UPDATED 04/02/08. *LJ THE CONSUMER WAS INFORMED THAT ENGINEERS HAD INSTALLED A HOSE ON THE FUEL SYSTEM THAT RELOCATED FUMES AWAY FROM THE FILL TUBE. THEIR EXPLANATION WAS THAT THE HOSE MAY HAVE BEEN FROZEN AND NOT ALLOWING THE TANK TO VENT. UPDATED
NHTSA ODI #10219118
12,000 miles · Jan 30, 2008
Power TrainCrash
TL*THE CONTACT OWNS A 2005 FORD EXPEDITION. WHILE DRIVING 5 MPH, THE VEHICLE SLID INTO A DITCH. THE REAR DRIVER'S SIDE LIGHTS AND BUMPER WERE DAMAGED. THE DEALER STATED THAT THE VEHICLE WAS SUPPOSED TO COME EQUIPPED WITH FOUR WHEEL DRIVE, BUT DID NOT. THE MANUFACTURER PAID TO INSTALL THE FOUR WHEEL DRIVE FEATURE IN DECEMBER …
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TL*THE CONTACT OWNS A 2005 FORD EXPEDITION. WHILE DRIVING 5 MPH, THE VEHICLE SLID INTO A DITCH. THE REAR DRIVER'S SIDE LIGHTS AND BUMPER WERE DAMAGED. THE DEALER STATED THAT THE VEHICLE WAS SUPPOSED TO COME EQUIPPED WITH FOUR WHEEL DRIVE, BUT DID NOT. THE MANUFACTURER PAID TO INSTALL THE FOUR WHEEL DRIVE FEATURE IN DECEMBER OF 2006. ON DECEMBER 1, 2007, THE VEHICLE SLID OUT OF THE DRIVEWAY INTO THE MIDDLE OF THE STREET. IN JANUARY OF 2008, THE VEHICLE WAS TAKEN TO THE DEALER AND THEY REINSTALLED THE FOUR WHEEL DRIVE. THE CONTACT RETRIEVED THE VEHICLE ON JANUARY 10, 2008 AND THE FOUR WHEEL DRIVE FAILED AGAIN SEVEN DAYS LATER. THE CURRENT MILEAGE WAS 33,900 AND FAILURE MILEAGE WAS 12,000. UPDATED 3/4/08 *CN THE DEALER HAS SINCE FIXED THE 4-WHEEL DRIVE.
NHTSA ODI #10216518
39,950 miles · Jan 29, 2008
Fuel System, Other
THE VEHICLE LOSES POWER WHILE YOU ARE DRIVING, THERE IS NO WARNING OF ANY TYPE. JUST ALL OF A SUDDEN YOUR TRUCK WON'T MOVE. THIS CAN CAUSE SOMEONE TO REAR END YOUR VEHICLE. *CN
NHTSA ODI #10216363
Mileage unknown · Jan 3, 2008
Service Brakes, Hydraulic
2005 FORD EXPEDITION WITH PEDAL DESIGN DEFECT. CONSUMER STATES THAT WHILE PRESSING THE BRAKE PEDAL THE ACCELERATOR PEDAL ALSO CAN GET DEPRESSED. DEALER TOLD HIM THEY COULD DO NOTHING IT WAS THE WAY THE PEDALS WERE SET UP. *KB THE CONSUMER EXPERIENCED THE PROBLEM ON 4 DIFFERENT OCCASIONS. THE CONSUMER STATED THE PEDALS WERE TOO…
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2005 FORD EXPEDITION WITH PEDAL DESIGN DEFECT. CONSUMER STATES THAT WHILE PRESSING THE BRAKE PEDAL THE ACCELERATOR PEDAL ALSO CAN GET DEPRESSED. DEALER TOLD HIM THEY COULD DO NOTHING IT WAS THE WAY THE PEDALS WERE SET UP. *KB THE CONSUMER EXPERIENCED THE PROBLEM ON 4 DIFFERENT OCCASIONS. THE CONSUMER STATED THE PEDALS WERE TOO CLOSE TOGETHER. *JB
NHTSA ODI #10213923
49,511 miles · Dec 11, 2007
Electrical SystemFuel System, GasolineVehicle Speed Control
I HAVE A 2005 FORD EXPEDITION, EDDIE BAUER. MOST RECENTLY (2 WEEKS AGO), MY CHECK ELECTRONIC THROTTLE LIGHT CAME ON, I CALLED MY LOCAL DEALER AND PLANNED TO TAKE IT IN THE NEXT DAY. I WORK CLOSE TO HOME AND HAVE LIMITED DRIVING DISTANCE. ON THE WAY HOME, THE THROTTLE WENT COMPLETELY OUT AND THE VEHICLE CUT OFF ON THE SIDE OF …
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I HAVE A 2005 FORD EXPEDITION, EDDIE BAUER. MOST RECENTLY (2 WEEKS AGO), MY CHECK ELECTRONIC THROTTLE LIGHT CAME ON, I CALLED MY LOCAL DEALER AND PLANNED TO TAKE IT IN THE NEXT DAY. I WORK CLOSE TO HOME AND HAVE LIMITED DRIVING DISTANCE. ON THE WAY HOME, THE THROTTLE WENT COMPLETELY OUT AND THE VEHICLE CUT OFF ON THE SIDE OF THE ROAD AND WAS UNABLE TO BE RESTARTED AND HAD TO BE TOWED. MY LOCAL DEALER DID FIX IT IN A TIMELY MANNER. HOWEVER...THIS IS NOT THE FIRST PROBLEM. WE BOUGHT IT BRAND NEW AND WITHIN A MONTH THE FUEL INJECTOR WENT OUT WHEN I WAS COMING BACK HOME FROM OUT OF TOWN, MY DRIVERS SIDE SEAT ADJUSTMENT WENT OUT TWICE AND HAD TO BE REPLACED. I AM SHORT AND HAD TO DRIVE WITH MY SEAT ALL THE WAY BACK. 2 CAM PHASERS HAD TO BE REPLACED BACK IN THE SUMMER AND THEN MOST RECENTLY THIS. I HAVE 2 SMALL CHILDREN AND WOULD PREFER A DEPENDABLE VEHICLE. I FILED A FORMAL COMPLAINT WITH FORD AND HEARD FROM THEM TODAY OF WHICH I WAS TOLD THAT HAVING 49,000 MILES ON MY VEHICLE IT WAS NOT UNUSUAL FOR PARTS TO GO BAD. I LIVE ON A HARD SURFACE ROAD AND DRIVE TO WORK, NORMAL DAY TO DAY ACTIVITIES AND OF COURSE VACATION. THE ONLY THING THEY WOULD DO WAS UPGRADE MY WARRANTY TO COVER THE TRANSMISSION. IT ALREADY HAS THE EXTENDED WARRANTY. I AM DISAPPOINTED THEY WOULD NOT STAND BY THEIR PRODUCT. I HAVE OWNED 2 TOYOYTA'S IN THE PAST AND PLAN TO GO BACK TO A TOYOTA AND A FORD COULD NOT BE GIVEN TO ME AGAIN. *TR
NHTSA ODI #10211478
47,000 miles · Dec 6, 2007
Engine And Engine Cooling
OUR 2005 FORD EXPEDITION EDDIE BAUER EXHIBITS THE SAME SYMPTOMS AS WERE REPORTED TODAY REGARDING "CAMSHAFT POSITION SENSOR ON FORD 7 LTR ENGINES 1997-2003 - ENGINE SHUTS DOWN WHILE DRIVING FORWARD , AT VARIABLE SPEED: VERY SLOW TO HIGHWAY SPEEDS. WILL RESTART ON FIRST TRY AFTER COMING TO COMPLETE STOP. MESSAGE PANEL SHOWS "CHEC…
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OUR 2005 FORD EXPEDITION EDDIE BAUER EXHIBITS THE SAME SYMPTOMS AS WERE REPORTED TODAY REGARDING "CAMSHAFT POSITION SENSOR ON FORD 7 LTR ENGINES 1997-2003 - ENGINE SHUTS DOWN WHILE DRIVING FORWARD , AT VARIABLE SPEED: VERY SLOW TO HIGHWAY SPEEDS. WILL RESTART ON FIRST TRY AFTER COMING TO COMPLETE STOP. MESSAGE PANEL SHOWS "CHECK THROTTLE LINKAGE" OR SIMILAR. FIRST OCCURRED AROUND JULY 07 SECOND TIME TOOK TRUCK TO FORD DEALER AUG 11 - THEY WERE UNABLE TO REPRODUCE PROBLEM AFTER TESTING FOR SEVERAL HOURS (AT LEAST THAT'S WHAT THE CHARGE SAID). ONE MONTH LATER IT HAPPENED AGAIN, HAS NOW INCREASED INTERMITTENT TO ONCE EVERY 2-3 WEEKS. INCIDENT DATES START APPROX JULY 2007 THROUGH YESTERDAY 12/05. *TR
NHTSA ODI #10211042
70,298 miles · Nov 17, 2007
Vehicle Speed Control
I WAS TRAVELING AT 60 MPH AND SUDDENLY I HEARD AN ALARM AND THE DASH INDICATED "CHECK ELECTRONIC THROTTLE CONTROL. AT THAT INSTANT THE VEHICLE STALLED. I WAS ABLE TO MANEUVER TO THE BURM. TRIED TO START BUT WOULD NOT RESPOND. FINALLY AFTER ABOUT TWO MINUTES I WAS ABLE TO START THE VEHICLE AND RETURN TO WORK. TOOK VEHICLE TO BASS…
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I WAS TRAVELING AT 60 MPH AND SUDDENLY I HEARD AN ALARM AND THE DASH INDICATED "CHECK ELECTRONIC THROTTLE CONTROL. AT THAT INSTANT THE VEHICLE STALLED. I WAS ABLE TO MANEUVER TO THE BURM. TRIED TO START BUT WOULD NOT RESPOND. FINALLY AFTER ABOUT TWO MINUTES I WAS ABLE TO START THE VEHICLE AND RETURN TO WORK. TOOK VEHICLE TO BASS FORD SHERFFIELD VILLAGE OHIO. THEY ARE INVESTIGATING. *TR
NHTSA ODI #10209236
56,600 miles · Aug 15, 2007
Electrical System
TURNED ON IGNITION, LARGE EXPLOSION , SMOKE CAME OUT FROM UNDER HOOD, SUBSEQUENT INVESTIGATION SHOWED BATTERY HAD EXPLODED- BLEW THE TOP COVER OF THE BATTERY OFF OF BASE AS WELL AS RIGHT FRONT SIDE. CRACKED THE CLEAR COAT ON HOOD DIRECTLY ABOVE THE BATTERY.*JB
NHTSA ODI #10199727
Mileage unknown · Aug 14, 2007
Structure
2005 FORD EXPEDITION WITH FACTORY DEFECTS CUSTOMER STATES THAT THE CAR SOMETIMES SHOCKS THE BODY WHILE GOING THROUGH THE CAR WASH**CC 08/14/07 ADD TO CUSTOMER SENT IN ADDITIONAL INFO**NAR**CC THE CONSUMER STATED PLEASE ASSIST IN RETRIEVING THE $29,000 PAID OUT FOR THE VEHICLE AS THEY HAVE LEARNED THE VEHICLE IS NOT A NEW VEHICL…
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2005 FORD EXPEDITION WITH FACTORY DEFECTS CUSTOMER STATES THAT THE CAR SOMETIMES SHOCKS THE BODY WHILE GOING THROUGH THE CAR WASH**CC 08/14/07 ADD TO CUSTOMER SENT IN ADDITIONAL INFO**NAR**CC THE CONSUMER STATED PLEASE ASSIST IN RETRIEVING THE $29,000 PAID OUT FOR THE VEHICLE AS THEY HAVE LEARNED THE VEHICLE IS NOT A NEW VEHICLE BUT WAS USED AND WAS SERIOUSLY DAMAGED. THE CONSUMER STATED IF IT RAINS OR GOES THROUGH A CAR WASH THERE IS AN ELECTRICAL SHOCK AND RUNNING THE VIN NUMBER INDICATES THAT THIS INFACT IS A USED VEHICLE NOT A NEW VEHICLE AS STATED BY THE DEALER. THE CONSUMER STATED THE ROOF SHAKES BADLY. *TR
NHTSA ODI #10200295
Mileage unknown · Aug 14, 2007
Child Seat
THE SEAT DOES NOT FIT PROPERLY IN THE VEHICLE, YOU HAVE TO PROP IT UP ON THE BACK OF THE SEAT, SO THE BABY IS SITTING CORRECTLY, THEN IT WILL CONTINUE TO SLIDE DOWN THEN THE BABIES HEAD WILL FALL FORWARD. IT ALSO DOES NOT HAVE THE 5 POINT HARNESS. *JB
NHTSA ODI #10199613
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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