NHTSA owner reports · September 18, 2026 snapshot.
What owners actually said
315 reports68,550 miles · Sep 2, 2014
Tires
TL* THE CONTACT OWNS A 2005 FORD EXPEDITION EQUIPPED WITH MIRADA, TIRE LINE: CROSS TOUR SLX, TIRE SIZE: 265/70R17, AND DOT NUMBER: CC70-V2L3011 TIRES. THE CONTACT STATED THAT THE PASSENGER SIDE REAR AND DRIVER SIDE REAR TIRES BOTH EXPERIENCED SEVERE SIDE WALL CRACKING AND SEPARATION. THE MANUFACTURER WAS MADE AWARE OF THE FAILUR…
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TL* THE CONTACT OWNS A 2005 FORD EXPEDITION EQUIPPED WITH MIRADA, TIRE LINE: CROSS TOUR SLX, TIRE SIZE: 265/70R17, AND DOT NUMBER: CC70-V2L3011 TIRES. THE CONTACT STATED THAT THE PASSENGER SIDE REAR AND DRIVER SIDE REAR TIRES BOTH EXPERIENCED SEVERE SIDE WALL CRACKING AND SEPARATION. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND STATED THAT THE VEHICLE WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 12T014000 (TIRES). THE FAILURE TIRE AND VEHICLE MILEAGE WAS 68,550.
NHTSA ODI #10630113
68,000 miles · Aug 29, 2014
Engine
TL* THE CONTACT OWNS A 2005 FORD EXPEDITION. WHILE DRIVING ON AN INCLINE, THE VEHICLE STALLED AND THE ELECTRONIC THROTTLE CONTROL INDICATOR ILLUMINATED. THE ENGINE RESUMED NORMAL OPERATION AFTER THE VEHICLE WAS RESTARTED. THE FAILURE OCCURRED SEVERAL TIMES. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT MADE…
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TL* THE CONTACT OWNS A 2005 FORD EXPEDITION. WHILE DRIVING ON AN INCLINE, THE VEHICLE STALLED AND THE ELECTRONIC THROTTLE CONTROL INDICATOR ILLUMINATED. THE ENGINE RESUMED NORMAL OPERATION AFTER THE VEHICLE WAS RESTARTED. THE FAILURE OCCURRED SEVERAL TIMES. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 68,000.
NHTSA ODI #10629372
110,000 miles · Aug 23, 2014
EnginePower Train
ACCELERATED ENGINE TO PASS, ENGINE COUGHED AND HEAVED. THE RPM CLIMBED BUT VEHICLE ACTED LIKE IT WAS DYING. CAR EVENTUALLY DIED. TURNED CAR OFF RE- STARTED IT. CHK ENGINE LIGHT CAME ON. ENGINE RAN ROUGH WANTED TO RAMP UP IN RPMS BUT STILL ACTED LIKE IT WAS GOING TO DIE. (THIS IS NOT THE FIRST TIME, IT IS VERY INTERMITTENT) THE L…
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ACCELERATED ENGINE TO PASS, ENGINE COUGHED AND HEAVED. THE RPM CLIMBED BUT VEHICLE ACTED LIKE IT WAS DYING. CAR EVENTUALLY DIED. TURNED CAR OFF RE- STARTED IT. CHK ENGINE LIGHT CAME ON. ENGINE RAN ROUGH WANTED TO RAMP UP IN RPMS BUT STILL ACTED LIKE IT WAS GOING TO DIE. (THIS IS NOT THE FIRST TIME, IT IS VERY INTERMITTENT) THE LAST TIME IT SEEMED SERIOUS AND CONTINUOUS THEY CHANGED THE TRANSMISSION. THE PROBLEM DID NOT LEAVE. I READ NUMEROUS POST ON THE WEB SITE AS THE PROBLEM CONTINUES TO COME BACK. NEVER SHOWING CODES. JUST RUNS LIKE CRAP. NUMEROUS IDENTICAL PROBLEMS ON THE INTERNET. BOUGHT A NEW MAF. NO HELP. REPLACED COIL PACKS NO HELP. CHECKED AND CLEANED VCT SOLENOIDS. NO HELP. REPLACED CAMSHAFT POSITION SENSOR. NO HELP. NO CHK ENG LIGHTS. WILL NOT EXCEED 3500 RPM. *TR
NHTSA ODI #10627774
108,000 miles · Aug 1, 2014
Air BagsCrashInjury
I WAS DRIVING MY 2005 FORD EXPEDITION WEST ON EISENHOWER BLVD AT ABOUT 25 MPH. I PROCEEDED THROUGH THE INTERSECTION OF EISENHOWER AND CLEVELAND AVE WHEN A PICK-UP TRUCK RAN A RED LIGHT AND COLLIDED WITH THE RIGHT FRONT OF MY VEHICLE. MY VEHICLE SUSTAINED EXTENSIVE DAMAGE TO THE FRONT BUMPER, RIGHT FRONT FENDER AND FRONT PASSEN…
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I WAS DRIVING MY 2005 FORD EXPEDITION WEST ON EISENHOWER BLVD AT ABOUT 25 MPH. I PROCEEDED THROUGH THE INTERSECTION OF EISENHOWER AND CLEVELAND AVE WHEN A PICK-UP TRUCK RAN A RED LIGHT AND COLLIDED WITH THE RIGHT FRONT OF MY VEHICLE. MY VEHICLE SUSTAINED EXTENSIVE DAMAGE TO THE FRONT BUMPER, RIGHT FRONT FENDER AND FRONT PASSENGER DOOR, COMPLETELY DISLODGING THE RIGHT FRONT WHEEL AND BUCKLING THE FRAME OF THE VEHICLE. I SUSTAINED INJURIES, INCLUDING A BRUISED STERNUM AND BRUISED LUNGS. NEITHER FRONT AIRBAG DEPLOYED, WHICH WOULD HAVE MITIGATED MY INJURIES!
NHTSA ODI #10618559
183,797 miles · Jul 21, 2014
Service Brakes
TL* THE CONTACT OWNS A 2005 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING AT AN UNKNOWN SPEED, THE BRAKES WERE ENGAGED BUT FAILED TO STOP THE VEHICLE. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE FAILURE AND CURRENT MILEAGE WAS 183,797.
NHTSA ODI #10614993
11,000 miles · Jun 3, 2014
Electrical SystemVehicle Speed Control
I WAS DRIVING MY 2005 FORD EXPEDITION AT 25MPH AND CAME TO A STOP LIGHT. I STOPPED. I TRIED TO ACCELERATE BUT I COULDN'T. MY RPM WHERE MOVING BUT CAR WOULD NOT. THEN THE CHECK ELECTRIC THROTTLE CONTROL MESSAGE POPPED ON. CAR FINALLY STARTED TO ACCELERATE BUT DIED OUT. IT THEN RESTARTED AND DROVE NORMALLY FOR 4 BLOCKS, BEFORE NOT…
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I WAS DRIVING MY 2005 FORD EXPEDITION AT 25MPH AND CAME TO A STOP LIGHT. I STOPPED. I TRIED TO ACCELERATE BUT I COULDN'T. MY RPM WHERE MOVING BUT CAR WOULD NOT. THEN THE CHECK ELECTRIC THROTTLE CONTROL MESSAGE POPPED ON. CAR FINALLY STARTED TO ACCELERATE BUT DIED OUT. IT THEN RESTARTED AND DROVE NORMALLY FOR 4 BLOCKS, BEFORE NOT ACCELERATING AT ALL. HAD TO BE TOWED TO FORD DEALER. THIS NEEDS TO BE RECALLED. *TR
NHTSA ODI #10595809
85,000 miles · May 18, 2014
EngineFuel/propulsion System
ELECTRONIC THROTTLE CONTROL HELP, I HAVE A 2005 EXPEDITION,. THE THING HAS JUST STARTED SHUTTING DOWN ON ME WHILE DRIVING. FOR NO APPARENT REASON, WHILE DRIVING ALONG, IT STOPS RUNNING, AND AFTER SHUTTING IT OFF, PLACING IT IN PARK, IT WILL START BACK UP. IT WAS SO SCARY , THANKS GOD I DIDN'T HAD ANY ACCIDENT ,THIS IS A B…
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ELECTRONIC THROTTLE CONTROL HELP, I HAVE A 2005 EXPEDITION,. THE THING HAS JUST STARTED SHUTTING DOWN ON ME WHILE DRIVING. FOR NO APPARENT REASON, WHILE DRIVING ALONG, IT STOPS RUNNING, AND AFTER SHUTTING IT OFF, PLACING IT IN PARK, IT WILL START BACK UP. IT WAS SO SCARY , THANKS GOD I DIDN'T HAD ANY ACCIDENT ,THIS IS A BIG ISSUE FROM FORD *JS
NHTSA ODI #10592264
155,000 miles · May 12, 2014
Vehicle Speed Control
TL* THE CONTACT OWNS A 2005 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 35 MPH, THE VEHICLE SPUTTERED WHEN THE ACCELERATOR PEDAL WAS APPLIED AND THEN STALLED WITH THE ILLUMINATION OF THE ENGINE FAIL SAFE LIGHT. THE VEHICLE WAS ABLE TO BE RESTARTED AFTER SEVERAL ATTEMPTS AND WAS TAKEN TO AN INDEPENDENT …
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TL* THE CONTACT OWNS A 2005 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 35 MPH, THE VEHICLE SPUTTERED WHEN THE ACCELERATOR PEDAL WAS APPLIED AND THEN STALLED WITH THE ILLUMINATION OF THE ENGINE FAIL SAFE LIGHT. THE VEHICLE WAS ABLE TO BE RESTARTED AFTER SEVERAL ATTEMPTS AND WAS TAKEN TO AN INDEPENDENT MECHANIC, WHO STATED THAT THE ELECTRONIC THROTTLE BODY NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED, HOWEVER THE VEHICLE STILL SPUTTERED INTERMITTENTLY. THE MANUFACTURER WAS NOTIFIED OF THE DEFECT. THE APPROXIMATE FAILURE MILEAGE WAS 155,000.
NHTSA ODI #10587877
112,925 miles · May 7, 2014
Fuel System, Gasoline
DRIVING UP A SMALL INCLINE AND THE VEHICLE LOST POWER. I HAD ELECTRICAL POWER JUST NO FUEL GETTING TO THE ENGINE. I WAS ABLE TO PULL OFF TO THE SIDE OF THE ROAD. THE FUEL TANK WAS JUST BELOW A 1/4 TANK. ADD A GALLON OF GAS AND TRIED TO RESTART THE CAR. IT WOULD NOT RESTART. CALLED FOR THE TOW TRUCK TO TAKE TO THE GARAGE. …
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DRIVING UP A SMALL INCLINE AND THE VEHICLE LOST POWER. I HAD ELECTRICAL POWER JUST NO FUEL GETTING TO THE ENGINE. I WAS ABLE TO PULL OFF TO THE SIDE OF THE ROAD. THE FUEL TANK WAS JUST BELOW A 1/4 TANK. ADD A GALLON OF GAS AND TRIED TO RESTART THE CAR. IT WOULD NOT RESTART. CALLED FOR THE TOW TRUCK TO TAKE TO THE GARAGE. THE GARAGE HAD TO DROP THE FUEL TANK AND TOLD ME THE FUEL PUMP CONTROL MODULE WAS BAD. THEY HANDED ME THE MODULE UPON PICKING UP MY VEHICLE AND I CAN TELL YOU WHY THE MODULE WENT BAD. IT HAS A HOLE IN IT FROM CORROSION. I HAVE SAID MODULE IF ANYONE FROM FORD OR NHTSA WOULD LIKE TO EXAMINE THE MODULE. *TR
NHTSA ODI #10587112
103,000 miles · Apr 5, 2014
Fuel/propulsion System
THE REPORTED MODEL WAS CRUISING AT 65 MILES AN HOUR ALONG NORTH BOUND I-795 @ NC RTE 42, WILSON, NC (STATE POLICE RESPONDED TO THIS DISABLED VEHICLE CALL) VEHICLE ACTED LIKE IT RAN OUT OF GAS. ELECTRICAL PROVEOUT INDICATORS WERE NORMAL. IGNITION SYSTEM WAS FUNCTIONAL, AS WERE ALL OTHER FACETS OF THE ELECTRICAL SYSTEM SEEMED FINE…
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THE REPORTED MODEL WAS CRUISING AT 65 MILES AN HOUR ALONG NORTH BOUND I-795 @ NC RTE 42, WILSON, NC (STATE POLICE RESPONDED TO THIS DISABLED VEHICLE CALL) VEHICLE ACTED LIKE IT RAN OUT OF GAS. ELECTRICAL PROVEOUT INDICATORS WERE NORMAL. IGNITION SYSTEM WAS FUNCTIONAL, AS WERE ALL OTHER FACETS OF THE ELECTRICAL SYSTEM SEEMED FINE DURING THE ENGINE POWER FAILURE, HOWEVER , LOSS OF STEERING POWER AND BRAKING POWER WAS EVIDENT AND PROMINENT. AFTER SAFELY COASTING OFF ONTO THE SHOULDER JUST PAST THE SAID INTERSECTION THE VEHICLE WOULD NOT START AND WAS TOWED TO A REPAIR FACILITY. A FINAL DIAGNOSIS WAS PERFORMED AND WAS DETERMINED OF A RELAY CONTACT FAILURE. THIS RELAY IS AN INTEGRAL PART OF THE MAIN POWER DISTRIBUTION PANEL / FUSE BLOCK RIGHT OF THE PASSENGER FOOT WELL. MAKING THIS PART INTEGRAL TO THE POWER BLOCK MAKES IT EXTREMELY EXPENSIVE TO REPAIR AND MAKES THE VEHICLE UNSAFE AS FAR AS A REASONABLE REPAIR TO A CRITICAL SYSTEM AND PLACES OTHER SYSTEMS AT RISK BY THE NATURE OF REPLACING THE ENTIRE POWER BLOCK TO REPAIR THE PROBLEM.. IE: THE FUEL PUMP. WHEN THIS RELAY CONTACT FAILS, POWER IS LOST TO THE FUEL PUMP DRIVER MODULE LOCATED UNDER THE DRIVER'S REAR WHEEL WELL. THIS MODULE SUPPLY POWER TO THE FUEL PUMP MOTOR IN THE FUEL TANK. THE FUEL PUMP CONTROL MODULE ITSELF SHOULD BE SCRUTINIZED HENCE IT'S LOCATION MAKES IT VULNERABLE TO WEATHER AND QUICK CORROSION. *TR
NHTSA ODI #10577711
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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