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 reports
144,239 miles · Feb 3, 2015
Engine
VEHICLE CHECK ENGINE LIGHT STAYS ON. VEHICLE TURNS OFF WHEN SITTING IDLE. BROUGHT VEHICLE TO DEALERSHIP AND THEY SAID THEY FIXED IT, BUT AFTER LEAVING THE DEALERSHIP AND PAYING A LARGE BILL THE CHECK ENGINE LIGHT CAME BACK ON AND STILL CUTS OFF WHEN JUST SITTING IDLE IN "DRIVE". SCARED THAT THIS CAN CAUSE AN ACCIDENT IF SOMEO…
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VEHICLE CHECK ENGINE LIGHT STAYS ON. VEHICLE TURNS OFF WHEN SITTING IDLE. BROUGHT VEHICLE TO DEALERSHIP AND THEY SAID THEY FIXED IT, BUT AFTER LEAVING THE DEALERSHIP AND PAYING A LARGE BILL THE CHECK ENGINE LIGHT CAME BACK ON AND STILL CUTS OFF WHEN JUST SITTING IDLE IN "DRIVE". SCARED THAT THIS CAN CAUSE AN ACCIDENT IF SOMEONE BEHINDS ME DOESN'T REALIZE THAT MY VEHICLE CUTS OFF. *TR
NHTSA ODI #10681015
171,745 miles · Jan 26, 2015
Engine
I HAVE HAD AN ENGINE CHECK LIGHT AND NO ONE CAN FIND THE PROBLEM. SOME MECHANICS TELL ME ITS ONE THING AND THE OTHERS SOMETHING ELSE. TOOK TO A.V FORD AND QUICKLANE IN NORTH HOLLYWOOD. MY TRUCK STAYED SEVERAL DAYS AT SHOP AND STILL CANT FIND PROBLEM. MECHANIC EVEN CALLED DETROIT PLANT TO GET ADVISE. STILL NOT RESOLVED. PAID TOO …
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I HAVE HAD AN ENGINE CHECK LIGHT AND NO ONE CAN FIND THE PROBLEM. SOME MECHANICS TELL ME ITS ONE THING AND THE OTHERS SOMETHING ELSE. TOOK TO A.V FORD AND QUICKLANE IN NORTH HOLLYWOOD. MY TRUCK STAYED SEVERAL DAYS AT SHOP AND STILL CANT FIND PROBLEM. MECHANIC EVEN CALLED DETROIT PLANT TO GET ADVISE. STILL NOT RESOLVED. PAID TOO MUCH JUST TRYING TO FIGURE THE PROBLEM. HAS THERE BEEN ANY ISSUES BROUGHT TO YOU ABOUT ENGINE LIGHT ON FOR FORD TRUCKS. I HAVE DOCUMENTS OF VISITS TO MECHANICS IF YOU GUYS NEED THEM. *TR
NHTSA ODI #10678972
90,000 miles · Nov 19, 2014
Electrical SystemEngineVehicle Speed Control
FOR THE 3RD TIME IN THE PAST YEAR I AM DRIVING DOWN THE ROAD AT ABOUT 40 MPH - ENGINE LIGHTS COMES ON, MESSAGE "CHECK ELECTRONIC THROTTLE CONTROL" COMES ON - I HAVE NO POWER, I COAST TO THE SIDE LANE TURN ON HAZARD LIGHTS, TURN KEY TO OFF POSITION. RESTART THE CAR (TAKES A COUPLE OF TRIES) AND CONTINUE - THIS IS EXTREMELY DANGE…
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FOR THE 3RD TIME IN THE PAST YEAR I AM DRIVING DOWN THE ROAD AT ABOUT 40 MPH - ENGINE LIGHTS COMES ON, MESSAGE "CHECK ELECTRONIC THROTTLE CONTROL" COMES ON - I HAVE NO POWER, I COAST TO THE SIDE LANE TURN ON HAZARD LIGHTS, TURN KEY TO OFF POSITION. RESTART THE CAR (TAKES A COUPLE OF TRIES) AND CONTINUE - THIS IS EXTREMELY DANGEROUS AND SHOULD BE ADDRESSED BY FORD ( I HAVE REPORTED THIS ISSUE) LOOKING ON LINE AND ON ONE SITE HTTP://WWW.CARCOMPLAINTS.COM/FORD/EXPEDITION/2005/ENGINE/VEHICLE_SPEED_CONTROL.SHTML THERE ARE 52 COMPLAINTS WITH THE SAME ISSUE. THERE ARE MANY OTHER SITES REPORTING THE SAME EXACT PROBLEM. I AM TAKING MY VEHICLE TO THE DEALER TOMORROW - WHAT ELSE SHOULD I BE DOING TO RESOLVE THIS ISSUE. - IT'S APPARENT THAT MANY OTHER PEOPLE ARE HAVING THIS SAME EXACT ISSUE- DOES IT TAKE SOMEONE DYING TO GET THE CAR MANUFACTURERS TO LISTEN TO THEIR CUSTOMERS? *TR
NHTSA ODI #10659429
111,520 miles · Nov 19, 2014
Electrical SystemEngine
WHILE MOVING IN TRAFFIC THE VEHICLE ENGINE CUT-OFF ON ITS OWN. MESSAGE CAME UP ON DASH DISPLAY, SOMETHING ABOUT "ELECT THROTTLE CONTROL". WAS MOVING VERY SLOWLY ON AN INTERSTATE HIGHWAY BAD TRAFFIC, WITH HEATERS (FRONT AND BACK) AND THE RADIO ON. I WAS ABLE TO COAST OFF TO THE SIDE OF THE HIGHWAY. TURNED OFF RADIO, HEATERS, THEN…
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WHILE MOVING IN TRAFFIC THE VEHICLE ENGINE CUT-OFF ON ITS OWN. MESSAGE CAME UP ON DASH DISPLAY, SOMETHING ABOUT "ELECT THROTTLE CONTROL". WAS MOVING VERY SLOWLY ON AN INTERSTATE HIGHWAY BAD TRAFFIC, WITH HEATERS (FRONT AND BACK) AND THE RADIO ON. I WAS ABLE TO COAST OFF TO THE SIDE OF THE HIGHWAY. TURNED OFF RADIO, HEATERS, THEN WAS ABLE TO RESTART THE VEHICLE. BATTERY CONDITION WAS FINE (REPLACED 2 YEARS AGO), NO OTHER WARNING. VEHICLE IS WELL-MAINTAINED, NEVER DRIVEN HARD OR USED FOR TOWING. TODAY I AM TAKING IT TO A FORD DEALER FOR EVALUATION. *TR
NHTSA ODI #10659173
Mileage unknown · Oct 27, 2014
Air BagsCrashInjury
WE WERE SITTING IN TRAFFIC AND WERE REAR-ENDED AT MILEAGE SPEED AND CRASHED INTO THE VEHICLE IN FRONT OF US. THE AIR BAGS DID NOT OPEN. *TR
NHTSA ODI #10650526
146,000 miles · Oct 20, 2014
EngineService Brakes
WHILE DRIVING ON THE HIGHWAY THE CAR COMPLETELY SHUT DOWN. ALL LIGHTS ON DASH LIT UP, RADIO WENT OFF. SECONDS LATER THE CAR RESTATED ITSELF AND THE RADIO WENT BACK ON. THIS HAPPENED TWICE ON 10/20/2014 AND ONCE ABOUT TWO WEEKS BEFORE THAT.. NO WARNING LIGHTS COME ON, NO BUMPS THE ROAD WAS SMOOTH, NO RAIN PUDDLES. IT JUST DIES AN…
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WHILE DRIVING ON THE HIGHWAY THE CAR COMPLETELY SHUT DOWN. ALL LIGHTS ON DASH LIT UP, RADIO WENT OFF. SECONDS LATER THE CAR RESTATED ITSELF AND THE RADIO WENT BACK ON. THIS HAPPENED TWICE ON 10/20/2014 AND ONCE ABOUT TWO WEEKS BEFORE THAT.. NO WARNING LIGHTS COME ON, NO BUMPS THE ROAD WAS SMOOTH, NO RAIN PUDDLES. IT JUST DIES AND RESTARTS ITSELF EACH TIME. FOR ABOUT 6 MONTHS NOW THE CAR DIES COMPLETELY WHEN I AM BACKING UP EVERY NOW AND THEN NOT EACH TIME. WE HAD 5 PEOPLE IN THE CAR AND GOT VERY SCARED. I HAVE HAD LOTS OF WORK DONE TO THE CAR AND HAVE RECEIPTS. MECHANIC SAID IT SOUNDS LIKE RAN ELECTRICS PROBLEM THAT COULD BE ONE OF A HUNDRED THINGS. PLEASE HELP WITH A SOLUTION. *TR
NHTSA ODI #10648749
50,000 miles · Oct 18, 2014
Structure
PAINT ON TAILGATE IS PEELING AND BUBBLING. *TR
NHTSA ODI #10648536
110,000 miles · Oct 3, 2014
Structure
PAINT IS CRACKING. *TR
NHTSA ODI #10641154
103,000 miles · Sep 16, 2014
Engine
TL* THE CONTACT OWNS A 2005 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING AT 60 MPH, THE VEHICLE STALLED WITHOUT WARNING. ADDITIONALLY AFTER RESTARTING THE VEHICLE, THE ELECTRONIC THROTTLE CONTROL WARNING LIGHT ILLUMINATED. THE FAILURE OCCURRED ON TWO OCCASIONS. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURE…
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TL* THE CONTACT OWNS A 2005 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING AT 60 MPH, THE VEHICLE STALLED WITHOUT WARNING. ADDITIONALLY AFTER RESTARTING THE VEHICLE, THE ELECTRONIC THROTTLE CONTROL WARNING LIGHT ILLUMINATED. THE FAILURE OCCURRED ON TWO OCCASIONS. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 103,000.
NHTSA ODI #10633722
72,000 miles · Sep 10, 2014
Engine And Engine CoolingCrash
TL* THE CONTACT OWNS A 2005 FORD EXPEDITION. THE CONTACT STATED THAT THE DRIVER CRASHED INTO ANOTHER VEHICLE THAT WAS PARKED. A POLICE REPORT WAS NOT FILED AND THERE WERE NO INJURIES REPORTED. THE VEHICLE WAS TAKEN TO A PRIVATE MECHANIC AND THE CONTACT WAS INFORMED THAT THE FRONT RADIATOR HAD BECOME ROTTEN. THE VEHICLE WAS NOT R…
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TL* THE CONTACT OWNS A 2005 FORD EXPEDITION. THE CONTACT STATED THAT THE DRIVER CRASHED INTO ANOTHER VEHICLE THAT WAS PARKED. A POLICE REPORT WAS NOT FILED AND THERE WERE NO INJURIES REPORTED. THE VEHICLE WAS TAKEN TO A PRIVATE MECHANIC AND THE CONTACT WAS INFORMED THAT THE FRONT RADIATOR HAD BECOME ROTTEN. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 72,000.
NHTSA ODI #10632264
Official recalls
0
No 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
1
PE08070 · 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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