NHTSA owner reports · September 18, 2026 snapshot.
Engine complaints
87 reportsClear category filterMileage unknown · Jan 8, 2024
EngineFuel/propulsion SystemSuspension
the service engine light continues to turn on. the timing belt continues to fail and has already been replaced once. the camshaft on both sides have been replaced. the solenoids have also been replaced and the diagnostics codes still pop up (p0022) (p0021) are just some that i can remember. the engine does not have enough power …
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the service engine light continues to turn on. the timing belt continues to fail and has already been replaced once. the camshaft on both sides have been replaced. the solenoids have also been replaced and the diagnostics codes still pop up (p0022) (p0021) are just some that i can remember. the engine does not have enough power on the driver side and throws the timing belt off which causes the loud rattle coming from the engine. when reaching the speed of 40-45 mph the truck begins to shake. recently in november 2023, when fueling up with gas , the truck began to shake and not respond. when accelerating, the truck takes off very slowly and the gears dont kick in on time. when the gas light comes on , the truck begins to function well. but as soon as i put gas again. it feels like the truck is going to fall apart. the driver door gets stuck when trying to open from the inside. the back door on the left does not open from the outside. the gear handle can be moved up and down while the truck is not turned on. please help!!
NHTSA ODI #11564296
130,000 miles · Oct 20, 2022
Engine
The contact owns a 2006 Ford Expedition. The contact stated while driving 55 MPH, the vehicle was driving sluggishly. The contact stated that the check engine warning light was illuminated. The vehicle was not drivable. The contact towed the vehicle to an independent mechanic and was informed that the ignition coil, the throttle…
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The contact owns a 2006 Ford Expedition. The contact stated while driving 55 MPH, the vehicle was driving sluggishly. The contact stated that the check engine warning light was illuminated. The vehicle was not drivable. The contact towed the vehicle to an independent mechanic and was informed that the ignition coil, the throttle body sensor (TBS) sensor, and the timing chain needed to be replaced. The vehicle was not repaired. The vehicle was not diagnosed or repaired at the dealer. A dealer was not contacted. The manufacturer had been informed of the failure. The contact stated on another occasion the vehicle failed to start. The vehicle was not drivable. The failure mileage was approximately 130,000.
NHTSA ODI #11490173
Mileage unknown · Jan 20, 2020
Engine
UPON RECEIVING TUNE UP THE SPARK PLUGS BROKE APART.AFTER GETTING THEM OUT CYL#1 WOULD NOT HOLD SPARK PLUG,CAUSED ME TO SPEND MORE MONEY TO GET PROBLEM FIXED.BUT THE SHOPS WILL NOT GUARANTEE THE WORK THAT IS NEEDED.THEY ALL SAID IT WAS A FACTORY ISSUE.THE TRUCK WAS STATIONARY AS WELL.
NHTSA ODI #11300564
245,000 miles · Jul 15, 2019
Electrical SystemEngine
TL* THE CONTACT CALLED ON BEHALF OF THE OWNER OF A 2006 FORD EXPEDITION. WHEN THE VEHICLE WAS STARTED, THERE WAS AN ODOR OF ANTIFREEZE IN THE VEHICLE. ADDITIONALLY, THE TEMPERATURE GAUGE AND CYLINDER HEAD TEMPERATURE SWITCH BECAME INOPERABLE. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO DIAGNOSED THAT THE INTAKE MANIFOLD…
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TL* THE CONTACT CALLED ON BEHALF OF THE OWNER OF A 2006 FORD EXPEDITION. WHEN THE VEHICLE WAS STARTED, THERE WAS AN ODOR OF ANTIFREEZE IN THE VEHICLE. ADDITIONALLY, THE TEMPERATURE GAUGE AND CYLINDER HEAD TEMPERATURE SWITCH BECAME INOPERABLE. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO DIAGNOSED THAT THE INTAKE MANIFOLD AND CYLINDER HEAD TEMPERATURE SWITCH NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE DEALER WAS NOT CONTACTED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 245,000.
NHTSA ODI #11232007
196,997 miles · Jul 16, 2018
EngineVehicle Speed Control
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. WHILE DRIVING APPROXIMATELY 60 MPH, THE VEHICLE'S SPEED DECELERATED TO 20 MPH. THE CONTACT COASTED THE VEHICLE TO THE SIDE OF THE ROAD AND TURNED OFF THE ENGINE. ONCE RESTARTED, THE VEHICLE WAS ABLE TO OPERATE NORMALLY. THE CONTACT STATED THAT THE FAILURE RECURRED AFTER DRIVING 30 MIL…
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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. WHILE DRIVING APPROXIMATELY 60 MPH, THE VEHICLE'S SPEED DECELERATED TO 20 MPH. THE CONTACT COASTED THE VEHICLE TO THE SIDE OF THE ROAD AND TURNED OFF THE ENGINE. ONCE RESTARTED, THE VEHICLE WAS ABLE TO OPERATE NORMALLY. THE CONTACT STATED THAT THE FAILURE RECURRED AFTER DRIVING 30 MILES DOWN THE ROAD AND THE VEHICLE STALLED WITHOUT WARNING. THE VEHICLE WAS NOT TAKEN TO A DEALER OR AN INDEPENDENT MECHANIC FOR DIAGNOSTIC TESTING. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT CONTACTED. THE APPROXIMATE FAILURE MILEAGE WAS 196,997.
NHTSA ODI #11111689
Mileage unknown · Jan 12, 2018
Electrical SystemEngineVehicle Speed Control
TAMARA RECALL
NHTSA ODI #11062497
172,000 miles · Aug 5, 2017
Engine
FORD HAD A RECALL FOR BROKEN SPARK PLUGS & A CLASS ACTION LAWSUIT ON THIS VEHICLE. FORD HAS FAILED TO FULLY COMPENSATE US & TOLD ME HARDLY NO ONE WOULD RECEIVE COMPENSATION. WE REPLACED THE PLUGS WITH FORD APPROVED REVISED PLUGS AT FORD WITH @ 149K MILES ON 11/2015. THE ENGINE CODES OR PROBLEMS WOULD COME UP NOW AND AGAIN & WE…
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FORD HAD A RECALL FOR BROKEN SPARK PLUGS & A CLASS ACTION LAWSUIT ON THIS VEHICLE. FORD HAS FAILED TO FULLY COMPENSATE US & TOLD ME HARDLY NO ONE WOULD RECEIVE COMPENSATION. WE REPLACED THE PLUGS WITH FORD APPROVED REVISED PLUGS AT FORD WITH @ 149K MILES ON 11/2015. THE ENGINE CODES OR PROBLEMS WOULD COME UP NOW AND AGAIN & WE HAD IT INTO VARIOUS VENDORS.. 2/ 2017, DRIVING BACK TO WYOMING I CAME UP AN I WAS UNDER LOAD (HAULING A TRAILER) AND THE AUTO ALMOST DID NOT MAKE IT HOME OR UP A GRADE. WE TOOK IT IN TO REPLACE THE COILS. THE VENDOR, MIDWAY MOTORS REPLACED THE COIL & NOTICED THE NEW REVISED FORD APPROVED SPARK PLUG 5 WAS BROKEN, AND PLUG 6 ALSO SHOWED A CODE, (MILEAGE 172627 MILES). THE ENGINE WAS DAMAGED SO WE TRADED THE FORD IN FOR A DODGE. MY POINT FORD HAS NOT FIXED THE ISSUE & IS DECEIVING THE PUBLIC. AND 2ND LAWSUIT CLAIM FORM IS [XXX] . THE VEHICLE WAS KEPT IN LIKE NEW SHAPE PRISTINE. I WAS SAD I HAD TO TRADE IT IN BUT DID NOT FEEL SAFE. I THINK YOU NEED TO KNOW HOW FORD IS PRACTICING AND NOT HANDLING ETHICALLY, LEGALLY, OR PROPERLY; BOTH THE CLASS ACTION LAWSUIT AND ALSO THE (REVISED SPARK PLUGS ARE ALSO FAILING). YES I HAVE DETAILED DOCUMENTS!! ASK ME I CAN EMAIL YOU PDF [XXX] [XXX] . INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6).'*JB
NHTSA ODI #11012978
100,464 miles · Jun 7, 2017
Engine
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. WHILE DRIVING OR WHILE THE VEHICLE WAS IDLING, THE CONTACT HEARD A TICKING NOISE COMING FROM THE ENGINE. THERE WERE NO WARNING INDICATORS ILLUMINATED. THE VEHICLE WAS TAKEN TO THE DEALER (KEN GRODY FORD AT 6211 BEACH BLVD, BUENA PARK, CA 90621) WHERE IT WAS DIAGNOSED THAT THE VALVE LA…
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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. WHILE DRIVING OR WHILE THE VEHICLE WAS IDLING, THE CONTACT HEARD A TICKING NOISE COMING FROM THE ENGINE. THERE WERE NO WARNING INDICATORS ILLUMINATED. THE VEHICLE WAS TAKEN TO THE DEALER (KEN GRODY FORD AT 6211 BEACH BLVD, BUENA PARK, CA 90621) WHERE IT WAS DIAGNOSED THAT THE VALVE LASH ADJUSTER AND THE TIMING CHAIN TENSIONERS NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER INFORMED THE CONTACT TO CALL NHTSA AND DID NOT OFFER ANY FURTHER ASSISTANCE. THE FAILURE MILEAGE WAS 100,464.
NHTSA ODI #10993713
117,000 miles · Apr 11, 2017
Electrical SystemEngine
WHILE IN TRAFFIC, AT LEAST 100 TIMES IN THE LAST FOUR YEARS (AT VARIABLE SPEEDS FROM 5 TO 65 MPH ON CITY STREETS AND FREEWAYS) MOST RECENTLY TWICE IN THE LAST WEEK, THE RPMS DROP BELOW 500 AND THE VEHICLE DIES AND "ENGINE FAILSAFE MODE" LIGHTS UP ON THE DASH. I HAVE TO EITHER COAST TO PULL OVER OR DEAD STOP IN THE MIDDLE OF THE …
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WHILE IN TRAFFIC, AT LEAST 100 TIMES IN THE LAST FOUR YEARS (AT VARIABLE SPEEDS FROM 5 TO 65 MPH ON CITY STREETS AND FREEWAYS) MOST RECENTLY TWICE IN THE LAST WEEK, THE RPMS DROP BELOW 500 AND THE VEHICLE DIES AND "ENGINE FAILSAFE MODE" LIGHTS UP ON THE DASH. I HAVE TO EITHER COAST TO PULL OVER OR DEAD STOP IN THE MIDDLE OF THE ROAD. I HAVE TO TURN THE VEHICLE COMPLETELY OFF (EVEN THOUGH IN FAILSAFE MODE ENGINE IS OFF, THE ELECTRONICS ARE STILL ON) AND THEN RESTART AND THEN IT WILL DRIVE JUST FINE UNTIL IT HAPPENS AGAIN. IT HAPPENS ANYWHERE FROM ONCE EVERY 6 MONTHS TO 6 TIMES IN 1 WEEK. IT SEEMS AS THOUGH IF I DRIVE WITH BOTH FEET IN TRAFFIC AND MAINTAIN ABOUT 800-1000 RMPS AT ALL TIMES IT DOESN'T DO THIS, HOWEVER THIS CANNOT BE DONE ALL THE TIME ESPECIALLY WHEN TRYING TO STOP THE LARGE VEHICLE QUICKLY OR TURNING IN AN INTERSECTION. NOTHING HAS BEEN DIAGNOSED BY DEALERSHIP AS NO CODES ARE THROWN. I ALSO OWN A OBD2 READER AND NO CODES HAVE EVER LISTED UNLESS ITS TIME TO CHANGE THE SPARK PLUGS. SEVERAL DIFFERENT MECHANICS, FORUMS AND BRAINSTORMING HAS NOT FIGURED IT OUT. I HAVE REPLACED MOSTLY EVERYTHING WITH EXCEPTION TO A NEW TRANSMISSION AND COMPUTER. MOSTLY EVERYTHING INCLUDING WIRES AND VACUUM LINES AND GASKETS HAVE BEEN REPLACED DUE TO MAINTENANCE OR REPAIRS FROM EVERYTHING ELSE THAT HAS GONE WRONG WITH IT. I HAVE PUT ABOUT $10K INTO NEW PARTS FOR THIS VEHICLE. I BOUGHT IT WITH 60K MILES ON IT AND IT NOW HAS 117K, ITS A DAILY DRIVER WITH 28 MILES OF TRAVEL 5 DAYS A WEEK. ALSO THE ONLY VEHICLE THAT FITS ALL OF THE CHILDREN FOR SOCCER, TRACK AND VOLLEYBALL TRAVELING TOURNAMENTS/GAMES. LUCKILY IT DOESN'T HAPPEN VERY OFTEN WHEN I'M NOT IN TRAFFIC SO THE KIDS AREN'T USUALLY WITH ME BUT IT IS VERY SCARY NOT TO KNOW IF YOU ARE GOING TO STOP OR IF THE PEOPLE BEHIND YOU ARE GOING TO HIT YOU OR NOT.
NHTSA ODI #10971943
194,000 miles · Jan 18, 2017
Engine
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT WHILE THE DRIVER WAS DRIVING AT AN UNKNOWN SPEED, THE VEHICLE STALLED AS THE FAIL SAFE MODE WARNING MESSAGE ILLUMINATED ACROSS THE INSTRUMENT PANEL. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE…
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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT WHILE THE DRIVER WAS DRIVING AT AN UNKNOWN SPEED, THE VEHICLE STALLED AS THE FAIL SAFE MODE WARNING MESSAGE ILLUMINATED ACROSS THE INSTRUMENT PANEL. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 194,000.
NHTSA ODI #10945943
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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