NHTSA owner reports · September 18, 2026 snapshot.
Engine And Engine Cooling complaints
75 reportsClear category filter93,000 miles · Jul 3, 2013
Engine And Engine Cooling
I BELIEVE THAT FORD EXPEDITIONS FROM YEARS 2003 - 2006 HAVE A SERIOUS DEFECT. I AM EXPERIENCING RADIATOR SUPPORT MOUNT ROT. MY MECHANIC SAYS THIS SHOULD NOT BE OCCURRING ON A VEHICLE THAT IS ONLY 6 YEARS OLD. I HAVE DONE SOME RESEARCH AND HAVE READ ON THE FORD EXPEDITION FORUM THAT MANY EXPEDITION DRIVERS ARE NOW FINDING THIS…
Read full complaint
I BELIEVE THAT FORD EXPEDITIONS FROM YEARS 2003 - 2006 HAVE A SERIOUS DEFECT. I AM EXPERIENCING RADIATOR SUPPORT MOUNT ROT. MY MECHANIC SAYS THIS SHOULD NOT BE OCCURRING ON A VEHICLE THAT IS ONLY 6 YEARS OLD. I HAVE DONE SOME RESEARCH AND HAVE READ ON THE FORD EXPEDITION FORUM THAT MANY EXPEDITION DRIVERS ARE NOW FINDING THIS TO BE THE CASE WITH THEIR VEHICLES AS WELL. I SERIOUSLY BELIEVE A RECALL SHOULD BE IN PLACE TO ADDRESS THIS PROBLEM. THE A/C CONDENSER IS NOW FALLING THROUGH AND THE BODY MOUNTS ARE BEING COMPROMISED. *TR
NHTSA ODI #10523121
105,300 miles · Nov 5, 2012
Engine And Engine Cooling
I BOUGHT MY TRUCK USED FROM A DEALERSHIP IN JANUARY 2012. I HAD DRIVEN IT FOR ABOUT 8 WEEKS WHEN IT COMPLETELY DIED ON ME AT A STOP LIGHT BEFORE TAKE OFF. EVERYTHING WAS ON EXCEPT IT WOULD NOT GO AND THE MESSAGE CAME UP SAYING FAIL SAFE MODE. IT DID IT A COUPLE WEEKS LATER TAKING OFF FROM A STOP SIGN AND THEN AFTER THAT IT SEEME…
Read full complaint
I BOUGHT MY TRUCK USED FROM A DEALERSHIP IN JANUARY 2012. I HAD DRIVEN IT FOR ABOUT 8 WEEKS WHEN IT COMPLETELY DIED ON ME AT A STOP LIGHT BEFORE TAKE OFF. EVERYTHING WAS ON EXCEPT IT WOULD NOT GO AND THE MESSAGE CAME UP SAYING FAIL SAFE MODE. IT DID IT A COUPLE WEEKS LATER TAKING OFF FROM A STOP SIGN AND THEN AFTER THAT IT SEEMED TO DO IT ONCE A MONTH. THIS LAST TIME ON FRIDAY OCTOBER 26, 2012 IT DID IT WHILE I WAS PULLING OUT OF A STORE INTO THE MIDDLE OF TRAFFIC. I WAS LUCKY ENOUGH MY 3 YEAR OLD SON WAS NOT IN THE CAR TO WHERE IT WOULD HAVE HURT HIM AS WELL AS OTHERS AND MYSELF. I HAVE READ MANY ARTICLES AND COMPLAINTS FROM OTHER EXPEDITION OWNERS ABOUT THE EXPEDITIONS GOING INTO FAIL SAFE MODE IN THE MIDDLE OF TRAFFIC. IT IS VERY CONCERNING THAT THEY DO THIS AND THE DEALERSHIP HAS EVEN MADE COMMENTS ABOUT IT WHEN IT WAS EXAMINED. MY MOTHER WORKS FOR FORD AND SHE HAS SEEN MULTIPLE ISSUES WITH THIS. FORD NEEDS TO ISSUE A RECALL ON THESE HOWEVER THEY WILL NOT SEE ANYTHING WRONG UNLESS MULTIPLE PEOPLE ARE INJURED OR EVEN DEAD. IT IS FRUSTRATING TO KNOW I PAID OVER $20,000 ON A VEHICLE THAT I LOVE AND NEED BUT IS NOT SAFE FOR MYSELF AND MY FAMILY. I HAVE PRICED A THROTTLE BODY WITH MY MOTHER'S DISCOUNT AT WORK AND IT WAS ABOUT $210.00 AFTER TAX AND THE LABOR TO PUT IT IN IS AROUND $450.00. IF FORD WOULD FIX THIS PROBLEM PEOPLE WOULD NOT HAVE TO PAY SO MUCH JUST TO BE SAFE IN A VEHICLE THEY SPEND SO MUCH MONEY. PLEASE LOOK INTO ISSUING SOMETHING AGAINST THIS VEHICLE PROBLEM SO THAT OTHERS ARE SAFE. *TR
NHTSA ODI #10483436
98,000 miles · Jul 19, 2012
Engine And Engine CoolingFuel/propulsion System
3RD TIME PROBLEMS WITH SPARK PLUGS AND FUEL INJECTOR....WAS TOLD BY DEALER THAT THIS YEAR MODEL THE INJECTORS ARE BAD FOR STICKING....LEAVING THE OWNER TO PAY FOR REPAIR COST AND THE EXPENSE OF CHANGING FORDS FAULTY SPARK PLUGS. *TR
NHTSA ODI #10466586
83,533 miles · May 2, 2012
Engine And Engine Cooling
I WAS ON HWY DOING 55 GETTING READY TO TAKE MY TURN OFF WHEN ENGINE SAFE MODE MESSAGE CAME ON. I THEN REALIZED THAT I HAD NO POWER EVEN THOUGH LIGHTS, RADIO, AND A/C WAS STILL ON. NOT BEING ABLE TO ACCELERATE I COASTED THE VEHICLE TO SIDE OF HWY AS FAR AS POSSIBLE, TURNED KEY TO OFF AND THAN BACK ON AND IT STARTED UP. I WAS AB…
Read full complaint
I WAS ON HWY DOING 55 GETTING READY TO TAKE MY TURN OFF WHEN ENGINE SAFE MODE MESSAGE CAME ON. I THEN REALIZED THAT I HAD NO POWER EVEN THOUGH LIGHTS, RADIO, AND A/C WAS STILL ON. NOT BEING ABLE TO ACCELERATE I COASTED THE VEHICLE TO SIDE OF HWY AS FAR AS POSSIBLE, TURNED KEY TO OFF AND THAN BACK ON AND IT STARTED UP. I WAS ABLE TO GET HOME WITHOUT FURTHER PROBLEM AND BACK TO WORK. UNFORTUNATELY I HAVE A 45 MINUTE DRIVE EVERY NIGHT AND EARLY MORNING TO AND FROM MY WORK WHICH IT COULD HAPPEN AGAIN AND NOT HAVE SUCH A GOOD CIRCUMSTANCE. THERE HAVE BEEN SEVERAL COMPLAINTS OVER SEVERAL YEARS TO FORD ON THIS WHY HAS IT NOT BEEN RECALLED? *JS
NHTSA ODI #10457105
109,000 miles · Apr 30, 2012
Engine And Engine Cooling
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING 55 MPH, THE VEHICLE STALLED IN THE MIDDLE OF THE ROAD. THE VEHICLE WAS SAFELY MERGED ONTO THE SHOULDER AND THE CONTACT TURNED THE ENGINE OFF. THE CHECK ENGINE LIGHT ILLUMINATED PRIOR TO THE FAILURE. THE VEHICLE WAS TAKEN TO THE DEALER, WHO REPLACE…
Read full complaint
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING 55 MPH, THE VEHICLE STALLED IN THE MIDDLE OF THE ROAD. THE VEHICLE WAS SAFELY MERGED ONTO THE SHOULDER AND THE CONTACT TURNED THE ENGINE OFF. THE CHECK ENGINE LIGHT ILLUMINATED PRIOR TO THE FAILURE. THE VEHICLE WAS TAKEN TO THE DEALER, WHO REPLACED THE OXYGEN SENSOR, SPARKS PLUGS, AND ENGINE COILS. THE FAILURE CONTINUED. THE VEHICLE WAS TAKEN BACK TO THE DEALER AND THE CATALYTIC CONVERTER WAS REPLACED. THE FAILURE CONTINUED. THE CONTACT PLANNED ON TAKING THE VEHICLE BACK TO THE DEALER. THE MANUFACTURER WAS NOTIFIED AND STATED THAT THERE WERE NO RECALLS ADDRESSING THE FAILURE. NO FURTHER ASSISTANCE WAS OFFERED. THE FAILURE MILEAGE WAS 109,000.
NHTSA ODI #10456870
Mileage unknown · Apr 25, 2012
Engine And Engine Cooling
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT WAS DRIVING 55 TO 65 MPH WHEN THE ENGINE SAFE MODE WARNING LIGHT ILLUMINATED AND THE ENGINE STALLED. THE VEHICLE RESTARTED AFTER THE FAILURE. THE FAILURE OCCURRED SEVEN DIFFERENT TIMES. THE VEHICLE WAS TAKEN TO THE DEALER. THE MANUFACTURER WAS ALSO NOTIFIED. THE VEHICLE WA…
Read full complaint
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT WAS DRIVING 55 TO 65 MPH WHEN THE ENGINE SAFE MODE WARNING LIGHT ILLUMINATED AND THE ENGINE STALLED. THE VEHICLE RESTARTED AFTER THE FAILURE. THE FAILURE OCCURRED SEVEN DIFFERENT TIMES. THE VEHICLE WAS TAKEN TO THE DEALER. THE MANUFACTURER WAS ALSO NOTIFIED. THE VEHICLE WAS NOT REPAIRED AND THE VIN WAS UNKNOWN. THE FAILURE AND CURRENT MILEAGES WERE UNKNOWN.
NHTSA ODI #10456443
82,000 miles · Feb 13, 2012
Engine And Engine Cooling
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT THE VEHICLE STALLED WHILE DRIVING AT VARIOUS SPEEDS AND THE ENGINE SAFE MODE WARNING INDICATOR ILLUMINATED. THE CONTACT STATED THAT THE FAILURE OCCURRED ON THREE PRIOR OCCASIONS. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER, WHO WAS UNABLE TO DIAGNOSE THE FAIL…
Read full complaint
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT THE VEHICLE STALLED WHILE DRIVING AT VARIOUS SPEEDS AND THE ENGINE SAFE MODE WARNING INDICATOR ILLUMINATED. THE CONTACT STATED THAT THE FAILURE OCCURRED ON THREE PRIOR OCCASIONS. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER, WHO WAS UNABLE TO DIAGNOSE THE FAILURE. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE, BUT OFFERED NO ASSISTANCE AND REFERRED THE CONTACT TO NHTSA. THE VEHICLE WAS NOT REPAIRED. THE FAILURE AND CURRENT MILEAGES WERE 82,000.
NHTSA ODI #10447835
55,000 miles · Feb 11, 2012
Engine And Engine Cooling
ENGINE FAIL SAFE MODE RESULTING IN COMPLETE SHUTDOWN WHILE GOING AT HIGHWAY SPEED. VEHICLE LOSSES ALL POWER AND HAS TO BE RESTARTED. *TR
NHTSA ODI #10447516
90,000 miles · Feb 6, 2012
Engine And Engine CoolingFire
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT THE VEHICLE WOULD ONLY SHIFT INTO REVERSE. UPON EXAMINING THE VEHICLE, THE CONTACT NOTICED THAT A WIRING HARNESS WITHIN THE ENGINE MELTED AGAINST THE EXHAUST MANIFOLD. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER AND THE CONTACT WAS INFORMED THAT THE WIRING HA…
Read full complaint
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT THE VEHICLE WOULD ONLY SHIFT INTO REVERSE. UPON EXAMINING THE VEHICLE, THE CONTACT NOTICED THAT A WIRING HARNESS WITHIN THE ENGINE MELTED AGAINST THE EXHAUST MANIFOLD. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER AND THE CONTACT WAS INFORMED THAT THE WIRING HARNESS NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND OFFERED NO ASSISTANCE. THE FAILURE MILEAGE WAS 90,000.
NHTSA ODI #10446777
40,000 miles · Jan 19, 2012
Engine And Engine Cooling
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. WHILE DRIVING APPROXIMATELY 25 MPH, THE VEHICLE STALLED WITHOUT WARNING. THE FAILURE RECURRED SPORADICALLY AND AT DIFFERENT SPEEDS. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC FOR DIAGNOSTICS. THE CONTACT WAS NOT AWARE OF THE REPAIRS NEEDED. THE VEHICLE WAS NOT REPAIRED. THE VIN…
Read full complaint
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. WHILE DRIVING APPROXIMATELY 25 MPH, THE VEHICLE STALLED WITHOUT WARNING. THE FAILURE RECURRED SPORADICALLY AND AT DIFFERENT SPEEDS. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC FOR DIAGNOSTICS. THE CONTACT WAS NOT AWARE OF THE REPAIRS NEEDED. THE VEHICLE WAS NOT REPAIRED. THE VIN WAS NOT AVAILABLE. THE APPROXIMATE FAILURE MILEAGE WAS 40,000.
NHTSA ODI #10444512
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