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2006 Ford Expedition

Owner reports · Recalls · Investigations

Similar to other model years

Owner complaints for the 2006 Ford Expedition do not stand out strongly from the model-year median of 155.

About this comparison →

When problems were reported

Mileage at the reported incident

263 reports with mileage · 36 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.

  • Engine. Review the 87 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Engine And Engine Cooling. Review the 75 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Electrical System. Review the 32 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

19 crash reports6 fire reports18 injury reports

Engine complaints

87 reports
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128,000 miles · Aug 6, 2013
Electrical SystemElectronic Stability Control (esc)Engine

LEMON! 2006 FORD EXPEDITION BEGINNING OF JUNE IT STARTED "BOGGING" DOWN WHILE DRIVING. WE TOOK IT TO AUTOZONE, MISFIRE. TOOK IT TO A MECHANIC WE KNOW AND HE TOLD US THE CODES SHOWED 6,7,8 SPARKPLUGS. TRYING TO SAVE $.THIS HELPED A LITTLE, STARTED DOING IT AGAIN BUT WORSE, THIS TIME IT WAS DECELERATING WE WERE GOING 75 & CHECK EN…

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LEMON! 2006 FORD EXPEDITION BEGINNING OF JUNE IT STARTED "BOGGING" DOWN WHILE DRIVING. WE TOOK IT TO AUTOZONE, MISFIRE. TOOK IT TO A MECHANIC WE KNOW AND HE TOLD US THE CODES SHOWED 6,7,8 SPARKPLUGS. TRYING TO SAVE $.THIS HELPED A LITTLE, STARTED DOING IT AGAIN BUT WORSE, THIS TIME IT WAS DECELERATING WE WERE GOING 75 & CHECK ENGINE LIGHT STARTED FLASHING & BOGGED DOWN TO 50 ON THE HWY ALMOST CAUSE SEVERAL WRECKS AS I TRIED TO PULL OVER TO THE SIDE (WITH MY KIDS IN THE CAR) TOOK IT INTO THE MECHANIC & OTHER SPARK PLUGS COIL PACKS & 1 INJECTOR GOT IT FIXED PICKED IT UP & DIDN'T EVEN GET DOWN THE ROAD & IT DID IT AGAIN.THIS TIME CHECK ENGINE LIGHT WENT OFF AFTER FLASHING.TOOK IT BACK TO HIM & NO CODES COULDN'T FIND ANYTHING.WENT HM & ALMOST GOT IN A WRECK AGAIN! IT DECELERATE TO 45 AFTER GOING 70. WE WENT HM, NEXT MORNING GOING TO TAKE IT BACK TO HIM AGAIN!! WHILE DRIVING, A/C TURNED OFF, DOOR SENSOR ALARM FAIL POPPED UP, ANOTHER SENSOR FAIL, &PULLED OVER PUT IN PARK & WOULDN'T COME OUT OF PARK.CALLED MECHANIC,AFTER SO MANY LOOK OVERS THINKING IT WAS PCM, SECURITY MODULE, HE GIVES UP AFTER 2 WKS OF WORKING ON IT.WE GET IT HM & START LOOKING ON HERE & FIND SO MUCH ABOUT THIS LIKE ITS GOING IN SAFE FAIL MODE WITHOUT SHUTTING OFF. START LOOKING AT ALL THE OTHER FORUMS & THIS YR MODEL HAD 362 COMPLAINS ON ANOTHER SITE & MANY ON HERE, SEVERAL OF THIS SAME DEAL.WE STARTED WITH FUSES #5 BLOWN, CHANGE BLOWS IMMEDIATELY, CHANGE AGAIN BLOWS AGAIN. START CHASING WIRES, CHANGE AGAIN STARTS UP.OKAY GREAT!!! NOW ROUGH IDLE, WAY BAD WHO CARES IT STARTS! DRIVE IT TO WORK, WE DESPERATELY NEED MY CAR & FORD CANT GET TO IT FOR 1 1/2 MONTHS.STARTS STALLING WHILE DRIVING AGAIN A/C SHUTS OFF AND SLOWS DOWN. FORD NEEDS TO FIX THIS BEFORE IT KILLS SOMEONE! THIS IS A MAJOR DEFECT THAT WILL KILL! I HAVE FOUND THIS SAME ISSUE ON THIS SAME SITE A LOT! WHY ISN'T ANYTHING BEING DONE? HELP!!!!!!!!! *TR

NHTSA ODI #10533790

101,000 miles · Jun 17, 2013
Engine

TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED WHILE DRIVING 55 MPH SHE ATTEMPTED TO ACCELERATE THE VEHICLE AND IT BEGAN TO LUNGE AND HESITATE. THE VEHICLE ALSO STALLED. THE FAILURE RECURRED NUMEROUS TIMES. THE VEHICLE WAS NOT REPAIRED. THE VIN WAS UNAVAILABLE. THE FAILURE AND CURRENT MILEAGE WAS 101,000.

NHTSA ODI #10520096

70,500 miles · Jun 7, 2013
Engine

TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED WHILE DRIVING APPROXIMATELY 60 MPH, THE VEHICLE STALLED AND THE CHECK ENGINE WARNING LIGHT ILLUMINATED. THE VEHICLE WAS TAKEN TO THE DEALER WHERE IT WAS DIAGNOSED THAT THE ENGINE AND SPARK PLUGS NEEDED TO BE REPLACED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. TH…

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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED WHILE DRIVING APPROXIMATELY 60 MPH, THE VEHICLE STALLED AND THE CHECK ENGINE WARNING LIGHT ILLUMINATED. THE VEHICLE WAS TAKEN TO THE DEALER WHERE IT WAS DIAGNOSED THAT THE ENGINE AND SPARK PLUGS NEEDED TO BE REPLACED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE VEHICLE WAS REPAIRED BUT THE FAILURE RECURRED. THE APPROXIMATE FAILURE MILEAGE WAS 70,500 AND THE CURRENT MILEAGE WAS 70,628. *TR

NHTSA ODI #10515622

95,000 miles · Jun 5, 2013
Engine

TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING 70 MPH, THE FAIL SAFE WARNING LIGHT ILLUMINATED AS THE VEHICLE STALLED. THE VEHICLE WAS RESTARTED AND OPERATED AS DESIGNED. THE FAILURE RECURRED THREE TIMES. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE A…

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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING 70 MPH, THE FAIL SAFE WARNING LIGHT ILLUMINATED AS THE VEHICLE STALLED. THE VEHICLE WAS RESTARTED AND OPERATED AS DESIGNED. THE FAILURE RECURRED THREE TIMES. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE AND CURRENT MILEAGE WAS 95,000.

NHTSA ODI #10515349

85,000 miles · Apr 24, 2013
Engine

TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING 60 MPH, THE ENGINE LIGHT ILLUMINATED AND THE STEERING BECAME DIFFICULT. THE VEHICLE WAS TAKEN TO A DEALER FOR DIAGNOSIS AND THE CONTACT WAS INFORMED THAT FIVE OF HER SPARK PLUGS HAD FRACTURED INSIDE THE CYLINDER. THE VEHICLE WAS REPAIRED. THREE MO…

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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING 60 MPH, THE ENGINE LIGHT ILLUMINATED AND THE STEERING BECAME DIFFICULT. THE VEHICLE WAS TAKEN TO A DEALER FOR DIAGNOSIS AND THE CONTACT WAS INFORMED THAT FIVE OF HER SPARK PLUGS HAD FRACTURED INSIDE THE CYLINDER. THE VEHICLE WAS REPAIRED. THREE MONTHS AFTER THE REPAIR, THE ENGINE LIGHT ILLUMINATED AND THE VEHICLE WAS RETURNED TO THE DEALER WHO STATED THAT THE SPARK PLUG FAILURE HAD CAUSED THE CATALYTIC CONVERTER TO FAIL AND IT WOULD NEED TO BE REPLACED. THE VEHICLE HAD NOT BEEN REPAIRED. THE FAILURE AND CURRENT MILEAGE WAS 85,000.

NHTSA ODI #10509385

103,000 miles · Apr 24, 2013
Engine

TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED WHILE DRIVING 65 MPH, THE ENGINE FAIL SAFE MODE LIGHT ILLUMINATED AND THE VEHICLE STOPPED ACCELERATING. THE VEHICLE WAS RESTARTED AND OPERATED AS DESIGNED. IT WAS THE SECOND TIME THE FAILURE HAD OCCURRED. THE MANUFACTURER WAS NOTIFIED AND ADVISED THE CONTACT TO TAKE…

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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED WHILE DRIVING 65 MPH, THE ENGINE FAIL SAFE MODE LIGHT ILLUMINATED AND THE VEHICLE STOPPED ACCELERATING. THE VEHICLE WAS RESTARTED AND OPERATED AS DESIGNED. IT WAS THE SECOND TIME THE FAILURE HAD OCCURRED. THE MANUFACTURER WAS NOTIFIED AND ADVISED THE CONTACT TO TAKE THE VEHICLE TO A DEALER FOR DIAGNOSIS. THE VEHICLE HAD NOT BEEN REPAIRED. THE FAILURE AND CURRENT MILEAGE WAS 103,000.

NHTSA ODI #10509382

98,000 miles · Apr 9, 2013
Engine

ENGINE SHUTS OFF WHILE DRIVING AND SHOWS 'ENGINE FAIL SAFE MODE'. THIS HAS HAPPENED 6 TIMES SINCE I BOUGHT THE VEHICLE IN MARCH 2012 (I'VE HAD THE VEHICLE A LITTLE OVER A YEAR NOW). IT HAS HAPPENED IN 1) A RESTAURANT PARKING LOT WHILE ON VACATION; 2) IN A PARKING GARAGE AT WORK; 3) IN A STORE PARKING LOT; 4) IN A STORE PARKING L…

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ENGINE SHUTS OFF WHILE DRIVING AND SHOWS 'ENGINE FAIL SAFE MODE'. THIS HAS HAPPENED 6 TIMES SINCE I BOUGHT THE VEHICLE IN MARCH 2012 (I'VE HAD THE VEHICLE A LITTLE OVER A YEAR NOW). IT HAS HAPPENED IN 1) A RESTAURANT PARKING LOT WHILE ON VACATION; 2) IN A PARKING GARAGE AT WORK; 3) IN A STORE PARKING LOT; 4) IN A STORE PARKING LOT; 5) ON A ROAD; 6) IN A STORE PARKING LOT. (#5/#6 JUST HAPPENED YESTERDAY TO MY WIFE WHILE SHOPPING WITH OUR 3YR. OLD SON). THIS IS A SERIOUS SAFETY ISSUE BECAUSE IT CAN HAPPEN ANY TIME, ANYWHERE, WITHOUT WARNING. I HAVE CONTACTED FORD AND OF COURSE THEY SAY THEY ARE NOT AWARE OF THE PROBLEM - EVEN THOUGH I HAVE FOUND HUNDREDS OF COMPLAINTS ON VARIOUS ONLINE FORUMS AND RIGHT HERE ON THE NHTSA WEBSITE. IT SEEMS (FROM MY RESEARCH ONLINE) THAT THE PROBLEM CAN BE FIXED BY REPLACING THE THROTTLE BODY AND TPS - WHICH IS A COSTLY REPAIR FOR WHICH I DO NOT HAVE THE MONEY (AFTER JUST BUYING NEW TIRES IN ADDITION TO A SEPARATE $500 REPAIR). FORD NEEDS TO RECALL AND FIX THIS ISSUE BEFORE SOMEONE IS INJURED OR KILLED!! *TR

NHTSA ODI #10505626

70,000 miles · Mar 27, 2013
Engine

WHILE TRAVELING ON THE HIGHWAY AT APPROXIMATELY 75 MPH IN A 2006 FORD EXPEDITION, THE VEHICLE'S ENGINE SUDDENLY AND WITHOUT WARNING SHUT DOWN. DUE TO THE LOSS OF POWER, THE STEERING AND BRAKES WERE EXTREMELY DIFFICULT TO CONTROL. THE VEHICLE COASTED ON THE HIGHWAY UNTIL I WAS SAFELY ABLE TO DIRECT THE VEHICLE TO THE SIDE OF THE…

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WHILE TRAVELING ON THE HIGHWAY AT APPROXIMATELY 75 MPH IN A 2006 FORD EXPEDITION, THE VEHICLE'S ENGINE SUDDENLY AND WITHOUT WARNING SHUT DOWN. DUE TO THE LOSS OF POWER, THE STEERING AND BRAKES WERE EXTREMELY DIFFICULT TO CONTROL. THE VEHICLE COASTED ON THE HIGHWAY UNTIL I WAS SAFELY ABLE TO DIRECT THE VEHICLE TO THE SIDE OF THE ROADWAY. AFTER STOPPING AND PARKING THE VEHICLE SAFELY, I WAS ABLE TO RESTART THE VEHICLE WITHOUT FURTHER INCIDENT. THIS OCCURED A TOTAL OF THREE TIMES IN MONTHS THAT FOLLOWED. I TOOK THE VEHICLE TO A FORD DEALERSHIP AND THEY COULD NOT FIND A PROBLEM WITH THE VEHICLE. AFTER RESEARCHING THE INCIDENT ONLINE, I LEARNED THAT THE THROTTLE CONTROL SWITCH MAY HAVE BEEN THE CAUSE OF THE PROBLEM. I NOTIFIED THE DEALERSHIP OF MY RESEARCH AND THEY DID NOT AGREE. I REPLACED THE SWITCH ON MY OWN AND I HAVE NOT ENCOUNTERED ANY ADDITIONAL ENGINE FAILURES SINCE. *TR

NHTSA ODI #10504652

33,000 miles · Mar 20, 2013
Engine

RELATING TO ARTICLE HTTP://EDITORIAL.AUTOS.MSN.COM/BLOGS/AUTOSBLOGPOST-ROS.ASPX?POST=9D5D443C-A8B6-43A1-8CC6-5942B4C36E39&ICID=AUTOS_4051 MY VEHICLE HAS EXPERIENCED THE SAME ISSUE DOZENS OF TIME. I TOOK THE VEHICLE TO A DEALERSHIP, GUS MACHADO FORD IN MIAMI, FL AND MENTIONED THIS ISSUE. I WAS TOLD THEY WERE NOT AWARE OF THE P…

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RELATING TO ARTICLE HTTP://EDITORIAL.AUTOS.MSN.COM/BLOGS/AUTOSBLOGPOST-ROS.ASPX?POST=9D5D443C-A8B6-43A1-8CC6-5942B4C36E39&ICID=AUTOS_4051 MY VEHICLE HAS EXPERIENCED THE SAME ISSUE DOZENS OF TIME. I TOOK THE VEHICLE TO A DEALERSHIP, GUS MACHADO FORD IN MIAMI, FL AND MENTIONED THIS ISSUE. I WAS TOLD THEY WERE NOT AWARE OF THE PROBLEM WITH THE CAR GOING INTO ENGINE FAILSAFE MODE AND LOOSING POWER WHILE THE VEHICLE WAS STILL RUNNING. THE VEHICLE WAS UNDER FACTORY WARRANTY AT THAT POINT AND THEY REFUSED TO FIX IT. AT THAT TIME, I WAS NOT REALLY AWARE OF THE PROBLEM. AFTER IT HAPPENED AGAIN AND AGAIN, I DID SOME RESEARCH ONLINE AND FOUND OUT THAT THOUSANDS OF OWNERS ARE HAVING THE SAME PROBLEM. AT THE TIME THE VEHICLE WAS OUT OF FACTORY WARRANTY. I CONTACTED FORD A COUPLE OF YEAR AGO AND AGAIN THEY TOLD ME THEY WERE NOT AWARE OF THE PROBLEM, EVEN IF THEY ARE HUNDREDS AND HUNDREDS OF OWNERS THAT HAVE REPORTED THIS PROBLEM TO FORD AS DESCRIBED IN DIFFERENT BLOGS ONLINE. WHEN THIS HAPPENS, I HAVE TO FIND A PLACE TO STOP SINCE THE VEHICLE DOES NOT RESPOND TO THE GAS PEDAL EVEN IF IT IS STILL RUNNING. THE VEHICLE MUST BE TURNED OFF AND STARTED AGAIN. THIS IS A HUGE SAFETY CONCERN FOR ME A MY FAMILY, EVEN MORE NOW WITH A NEWBORN. IF IT HAPPENS WHILE ON THE EXPRESSWAY OR HIGHWAY, WE CAN BE REAR ENDED BY ANOTHER DRIVE OR TRUCK SINCE THE VEHICLE LOOSES POWER AND THE VEHICLE MUST BE TURNED OFF. HERE IN MIAMI, THERE IS A LOT OF CONSTRUCTION GOING ON AND HIGHWAYS ARE BEING EXPANDED. MUST OF THE CONSTRUCTION HAS ELIMINATED THE EMERGENCY LANE, WHICH MEANS THAT IF THAT HAPPENS, WE ARE GOING TO BE STRANDED IN THE MIDDLE OF THE HIGHWAY. I CONTACTED FORD AGAIN A FEW WEEKS AGO AND MENTIONED THE PROBLEM AGAIN, THEY STILL ""DON'T KNOW"" ABOUT THIS EVEN IF IT IS BEING INVESTIGATED BY THE NHTSA. PLEASE HELP. MY VEHICLE IS A FORD EXPEDITION 2006. *TR

NHTSA ODI #10503750

71,000 miles · Mar 11, 2013
Engine

TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 25 MPH, THE ENGINE LOST POWER. THE CONTACT ALSO STATED THAT THE ACTIVATING FAIL SAFE MODE WARNING LIGHT ILLUMINATED. THE VEHICLE WAS TAKEN TO A MECHANIC FOR DIAGNOSIS. THE MECHANIC WAS UNABLE TO DIAGNOSE THE FAILURE. THE MANUFACTURER…

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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 25 MPH, THE ENGINE LOST POWER. THE CONTACT ALSO STATED THAT THE ACTIVATING FAIL SAFE MODE WARNING LIGHT ILLUMINATED. THE VEHICLE WAS TAKEN TO A MECHANIC FOR DIAGNOSIS. THE MECHANIC WAS UNABLE TO DIAGNOSE THE FAILURE. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE APPROXIMATE MILEAGE WAS 71,000.

NHTSA ODI #10502343

Official recalls

2

05V520000 · Visibility:windshield Wiper/washer:motor

Nov 9, 2005

ON CERTAIN TRUCKS, PASSENGER CARS AND SPORT UTILITY VEHICLES, THE WINDSHIELD WIPER MOTOR MAY HAVE BEEN PRODUCED WITHOUT GREASE BEING APPLIED TO THE OUTPUT SHAFT GEAR.

Consequence & remedy

Consequence: AFTER A PERIOD OF CONTINUOUS USE ON THE HIGH SPEED SETTING, LACK OF GREASE ON THE OUTPUT SHAFT GEAR MAY CAUSE THE GEAR TO DISTORT OR FRACTURE DURING OPERATION RESULTING IN A LOSS OF WIPER FUNCTION. INOPERATIVE WIPERS UNDER INCLEMENT WEATHER CONDITIONS COULD CAUSE A CRASH DUE TO IMPAIRED VISIBILITY.

Remedy: DEALERS WILL INSPECT THE WIPER MOTOR FOR THE PRESENCE OF GREASE AND GREASE THE WIPER MOTOR GEARS IF NECESSARY. THE RECALL BEGAN ON NOVEMBER 22, 2005. OWNERS MAY CONTACT FORD AT 1-800-392-3673 OR LINCOLN/MERCURY AT 1-800-521-4140.

05V310000 · Tires:tread/belt

Jul 6, 2005

ON CERTAIN SPORT UTILITY VEHICLES, THE FRONT AND REAR TIRES ON THE DRIVER'S SIDE OF AFFECTED VEHICLES MAY HAVE BEEN DAMAGED AT THE CENTER TREAD DURING PRODUCTION.

Consequence & remedy

Consequence: OVER TIME, THE DAMAGE MAY BE SUFFICIENT TO ALLOW BELT CORROSION ULTIMATELY LEADING TO A TREAD SEPARATION, WHICH COULD RESULT IN A CRASH.

Remedy: DEALERS WILL INSPECT ALL FOUR TIRES (TO ENSURE INSPECTION OF THE LEFT HAND SIDE TIRES THAT MAY HAVE BEEN ROTATED TO THE OTHER SIDE OF THE VEHICLE) FOR TIRE TREAD DAMAGE AND, IF NECESSARY, REPLACE THE DAMAGED TIRE. THE RECALL BEGAN ON JULY 13, 2005. OWNERS MAY CONTACT FORD AT 1-800-392-3673.

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