NHTSA owner reports · September 18, 2026 snapshot.
Engine complaints
87 reportsClear category filter82,000 miles · Apr 21, 2014
Engine
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING 50 MPH, THE FAIL SAFE WARNING LAMP ILLUMINATED AS THE VEHICLE STALLED. THE VEHICLE WAS TAKEN TO THE DEALER WHERE THE TECHNICIAN DIAGNOSED THAT THE SPARK PLUGS NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED BUT THE FAILURE RECURRED. THE MANUFACTUR…
Read full complaint
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING 50 MPH, THE FAIL SAFE WARNING LAMP ILLUMINATED AS THE VEHICLE STALLED. THE VEHICLE WAS TAKEN TO THE DEALER WHERE THE TECHNICIAN DIAGNOSED THAT THE SPARK PLUGS NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED BUT THE FAILURE RECURRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 82,000 AND THE CURRENT MILEAGE WAS 83,000.
NHTSA ODI #10583919
133,237 miles · Apr 3, 2014
EngineSteering
AS I WAS DRIVING MY EXPEDITION, THE TRUCK SUDDENLY SHUT COMPLETELY OFF AND I HAD TO POWER STEERING AND THEN IN THE MESSAGE CENTER IT SHOWED "ENGINE FAILSAFE MODE". I HAD TO PUT MY FLASHERS ON AND COAST TO A STOP IN THE LANE I WAS IN AND COME TO A COMPLETE STOP BEFORE I COULD RESTART MY TRUCK. I WAS UNABLE TO SWITCH LANES OR MO…
Read full complaint
AS I WAS DRIVING MY EXPEDITION, THE TRUCK SUDDENLY SHUT COMPLETELY OFF AND I HAD TO POWER STEERING AND THEN IN THE MESSAGE CENTER IT SHOWED "ENGINE FAILSAFE MODE". I HAD TO PUT MY FLASHERS ON AND COAST TO A STOP IN THE LANE I WAS IN AND COME TO A COMPLETE STOP BEFORE I COULD RESTART MY TRUCK. I WAS UNABLE TO SWITCH LANES OR MOVE TO A SAFER LOCATION BECAUSE I HAD NO POWER STEERING. I HAD THE SAME THING HAPPEN IN MARCH OF 2009 WHEN I WAS GOING 60 ON THE INTERSTATE IN THE MIDDLE LANE AND LOST ALL POWER AND HAD TO COAST TO A STOP IN THAT LANE WITH MY FLASHERS ON HOPING EVERYONE AROUND ME WOULD SEE I WAS HAVING CAR TROUBLE. I HAD 3 OF MY KIDS IN THE TRUCK WITH ME. IN 2009 I TOOK IT INTO THE FORD DEALERSHIP AND THEY SAID IT WAS THE THROTTLE BODY AND REPLACED IT WHICH COST ME $536.00. IN 2009 IT HAPPENED 5 TIMES BEFORE IT WAS FIXED. I TOOK THE TRUCK IN TODAY AND THEY SAID AGAIN ITS THE THROTTLE BODY AND BECAUSE IT'S BEEN 5 YEARS THE OTHER ONE IS NO LONGER UNDER WARRANTY. SO NOW I'M GETTING A NEW THROTTLE BODY PUT IN. I EMAILED FORD CORPORATE AND WAS BASICALLY TOLD THAT THERE IS NO CURRENT RECALL NOR PLANS FOR ONE SO THERE'S NOTHING THEY CAN DO FOR ME! *TR
NHTSA ODI #10577260
74,300 miles · Mar 27, 2014
EngineSteeringVehicle Speed Control
THIS IS THE SECOND INCIDENT: THE FIST WAS ABOUT 3 MONTHS AGO. I WAS DRIVING DOWN A RESIDENTIAL STREET YESTERDAY WHEN THE "FAIL SAFE MODE" INDICATOR CAME ON AND SAID ENGINE SHUTTING DOWN. CAR TURNS OFF, CANNOT STEER. VERY DANGEROUS. I WAS ON A RESIDENTIAL STREET AND WAS ABLE TO PULL OFF. TURNED THE CAR OFF FOR A FEW MINUTES A…
Read full complaint
THIS IS THE SECOND INCIDENT: THE FIST WAS ABOUT 3 MONTHS AGO. I WAS DRIVING DOWN A RESIDENTIAL STREET YESTERDAY WHEN THE "FAIL SAFE MODE" INDICATOR CAME ON AND SAID ENGINE SHUTTING DOWN. CAR TURNS OFF, CANNOT STEER. VERY DANGEROUS. I WAS ON A RESIDENTIAL STREET AND WAS ABLE TO PULL OFF. TURNED THE CAR OFF FOR A FEW MINUTES AND IT STARTED AND I DROVE TO WORK, BUT THE ENGINE LIGHT REMAINED ON. I TOOK IT TO AN AUTO PARTS STORE WHO RAN IT AND IT CAME UP AS THROTTLE BODY FORCES IMMEDIATE IDLE. WHICH IS EXACTLY WHAT THE 10 PAGES ON COMPLAINTS ON CARCOMPLAINTS.COM SAID IT WOULD SAY - HOWEVER INFORMATION ON THAT SITE ALSO SAID IT'S ACTUALLY THE FUEL PUMP MODULATOR, BUT THE COMPUTER DID NOT INDICATE THAT AT ALL. THERE WERE ALMOST 60 COMPLAINTS OF THE SAME SITUATIONS - WHEN I PULLED OUT INTO TRAFFIC TODAY THE CAR 'HESITATED' AND DID NOT ACCELERATE CORRECTLY. THE FIRST INCIDENT OCCURRED ON A MAJOR HIGHWAY - AND AGAIN I WAS LUCKY ENOUGH TO BE IN THE RIGHT LANE AND WAS ABLE TO PULL OVER. THIS DEFECT IS GOING TO CAUSE AN INJURY OR EVEN DEATH AND IT NEEDS TO BE RECALLED AND CORRECTED. I WILL BE CONTACTING FORD CORPORATE; BUT WITH THE RECENT INCIDENTS WITH GM I WOULD HATE TO SEE AN ACCIDENT OR FATALITY OCCUR WHEN FORD AND OTHERS ARE AWARE OF THIS PROBLEM. OBVIOUSLY I HAVE TO GET THIS FIXED, I'M HOPING MY FORD DEALER WILL WORK WITH ME, BUT I HAVE A 4 YEAR OLD SO TIME IS OF THE ESSENCE AND I'M GUESSING MONEY WILL BE TOO. REGARDLESS OF FORD'S CORPORATE RESPONSE, I WILL BE CONTACTING THE MEDIA. THIS IS A SAFETY ISSUE AND IS UNACCEPTABLE THAT FORD IS NOT TAKING RESPONSIBILITY. *TR
NHTSA ODI #10575089
132,000 miles · Feb 28, 2014
EngineSteeringVehicle Speed Control
I WAS DRIVING AROUND 46MPH, AND IN THE MIDDLE OF DRIVING, MY TRUCK CUT OFF FOR AROUND 5 SECONDS. I ALMOST GOT BY THE TRUCK BEHIND ME. MY TRUCK KICKED BACK ON BY ITSELF, ALL WHY I WAS DRIVING. I WAS SO TERRIFIED THE TRUCK BEHIND ALMOST REAR ENDED ME. *TR
NHTSA ODI #10566562
70,000 miles · Jan 3, 2014
Engine
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT THE VEHICLE WOULD ENGAGE INTO SAFE MODE WHEN STARTED, CAUSING THE VEHICLE TO STALL. THE FAILURE WAS RECURRING OVER A THREE YEAR SPAN. THE VEHICLE WAS TAKEN TO A DEALER AND REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE PROBLEM. THE APPROXIMATE FAILURE WAS 70,…
Read full complaint
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT THE VEHICLE WOULD ENGAGE INTO SAFE MODE WHEN STARTED, CAUSING THE VEHICLE TO STALL. THE FAILURE WAS RECURRING OVER A THREE YEAR SPAN. THE VEHICLE WAS TAKEN TO A DEALER AND REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE PROBLEM. THE APPROXIMATE FAILURE WAS 70,000.
NHTSA ODI #10558303
125,000 miles · Dec 2, 2013
Engine
WHILE DRIVING APPROXIMATELY 35 KPH MY ABS LIGHT CAME ON FOLLOWED BY THE BRAKE LIGHT THEN THE AIRBAG LIGHT. (CHECK ENGINE NEVER GOES OFF. REPLACE ALL PLUGS AND COILS. REPLACE OF SENSORS AND SEVERAL FUSES.) THE HEADLIGHTS BEGIN TO FLASH OFF AND ON THEN TRUCK STARTED SPUTTERING. THE FUEL LIGHT WENT FROM 3/4 TANK TO E. I PULLED INTO…
Read full complaint
WHILE DRIVING APPROXIMATELY 35 KPH MY ABS LIGHT CAME ON FOLLOWED BY THE BRAKE LIGHT THEN THE AIRBAG LIGHT. (CHECK ENGINE NEVER GOES OFF. REPLACE ALL PLUGS AND COILS. REPLACE OF SENSORS AND SEVERAL FUSES.) THE HEADLIGHTS BEGIN TO FLASH OFF AND ON THEN TRUCK STARTED SPUTTERING. THE FUEL LIGHT WENT FROM 3/4 TANK TO E. I PULLED INTO SHOPPING CENTER PLACED IT IN PARK. WENT TO PUT IT BACK IN DRIVE AND COULDN'T SOMETHING WAS DRAINING BATTERY THAT IS ONLY 3 MONTHS OLD. DON'T KNOW RESOLUTION BUT TIRED OF THIS TRUCK! IT IS RIDICULOUS THAT THIS TRUCK HAS SO MANY REPEAT ISSUES AND NO RECALL. FORD NEEDS TO BE SUED. I DAILY HAVE TO TURN ON MY HAZARDS AND RESTART CAR BECAUSE IT SPONTANEOUSLY GOES INTO LIMP MODE, ESPECIALLY IN TRAFFIC. *TR
NHTSA ODI #10554452
82,000 miles · Nov 21, 2013
Engine
DRIVING AT 25MPH THE VEHICLE ENGINE SHUT DOWN AND WENT INTO FAILSAFE MODE, POWER STEERING ALSO DISABLED CAUSING A VERY DANGEROUS SITUATION TRYING TO STEER THE CAR FROM TRAFFIC TO A SAFE AREA WITHOUT ASSISTED STEERING. THIS PROBLEM HAS OCCURRED SEVERAL TIMES OVER THE PAST 2 YEARS AND USUALLY IN COLDER WEATHER. LAST TIME IT HAPPEN…
Read full complaint
DRIVING AT 25MPH THE VEHICLE ENGINE SHUT DOWN AND WENT INTO FAILSAFE MODE, POWER STEERING ALSO DISABLED CAUSING A VERY DANGEROUS SITUATION TRYING TO STEER THE CAR FROM TRAFFIC TO A SAFE AREA WITHOUT ASSISTED STEERING. THIS PROBLEM HAS OCCURRED SEVERAL TIMES OVER THE PAST 2 YEARS AND USUALLY IN COLDER WEATHER. LAST TIME IT HAPPENED WAS ON A MAIN HIGHWAY BUT LUCKILY I WAS ALONE WITHOUT MY FAMILY AND IN THE INSIDE LANE SO I WAS ABLE TO PULL OVER THANKFULLY IT DIDN'T HAPPEN IN THE OVERTAKING LANE AS THERE IS NO TIME TO SAFELY CHANGE LANES WHEN IT SHUTS DOWN. SURPRISED THERE HAS BEEN NO FATALITIES DUE TO THIS AS IT IS A COMMON PROBLEM WITH 2006 FORD TRUCKS. *TR
NHTSA ODI #10553237
60,000 miles · Nov 7, 2013
Engine
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING BETWEEN 45 TO 50 MPH, THE VEHICLE STALLED AND THE ENGINE FAIL SAFE LIGHT ILLUMINATED. THE CONTACT WAS ABLE TO COAST TO THE SHOULDER WHERE THE VEHICLE WAS RESTARTED. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER WHO STATED THAT THE THROTTLE BODY W…
Read full complaint
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING BETWEEN 45 TO 50 MPH, THE VEHICLE STALLED AND THE ENGINE FAIL SAFE LIGHT ILLUMINATED. THE CONTACT WAS ABLE TO COAST TO THE SHOULDER WHERE THE VEHICLE WAS RESTARTED. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER WHO STATED THAT THE THROTTLE BODY WAS NOT OPENING AND CLOSING CORRECTLY. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 60,000 AND THE CURRENT MILEAGE WAS 75,000.
NHTSA ODI #10551251
110,000 miles · Oct 21, 2013
Engine
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING 30 MPH, THE FAIL SAFETY ENGINE WARNING LIGHT ILLUMINATED AS THE VEHICLE STALLED. THE FAILURE WAS RECURRING. THE VEHICLE WAS NEITHER DIAGNOSED NOR REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED. THE FAILURE MILEAGE WAS 110,000.
NHTSA ODI #10548694
114,000 miles · Oct 15, 2013
Electrical SystemEngineVehicle Speed Control
VEHICLE SIMPLY SHUTS OFF AT ANY TIME AND SHOWS 'ENGINE FAIL SAFE MODE'. THIS HAS HAPPENED APPROXIMATELY 15 TIMES SINCE WE BOUGHT THE VEHICLE (USED) IN MARCH 2012 (MOST RECENTLY ON 10/13). I HAVE RESEARCHED THIS ONLINE AND MANY OTHER OWNERS HAVE THE SAME COMPLAINT. WE REPLACED THE TPS AT A COST OF AROUND $300 AS A POSSIBLE FIX AN…
Read full complaint
VEHICLE SIMPLY SHUTS OFF AT ANY TIME AND SHOWS 'ENGINE FAIL SAFE MODE'. THIS HAS HAPPENED APPROXIMATELY 15 TIMES SINCE WE BOUGHT THE VEHICLE (USED) IN MARCH 2012 (MOST RECENTLY ON 10/13). I HAVE RESEARCHED THIS ONLINE AND MANY OTHER OWNERS HAVE THE SAME COMPLAINT. WE REPLACED THE TPS AT A COST OF AROUND $300 AS A POSSIBLE FIX AND THIS WORKED FOR ABOUT 6 MONTHS - NOW THE PROBLEM IS BACK AND MY RESEARCH INDICATES WE NEED TO HAVE THE THROTTLE BODY REPLACED. THIS WILL COST US AROUND $500 - FOR A TOTAL REPAIR COST OF AROUND $800 - WHICH WE CANNOT AFFORD! FORD HAS LITERALLY $HUNDREDS OF MILLIONS TO TAKE CARE OF THIS AND MUST RECALL DUE TO THIS ISSUE - THERE IS NO EXCUSE TO ALLOW THIS DANGEROUS PROBLEM TO CONTINUE. FORD MOTOR CO. OWES ME $800 DUE TO THEIR POOR ENGINEERING AND UNWILLINGNESS TO SOLVE THIS ISSUE - THEY ARE GREEDY CROOKS. *TR
NHTSA ODI #10547909
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
Illustration