NHTSA owner reports · September 18, 2026 snapshot.
Fuel System, Gasoline complaints
15 reportsClear category filter70,000 miles · Aug 21, 2023
Fuel System, Gasoline
The contact owns a 2006 Ford Expedition. The contact stated that while driving 35 MPH, the contact stated that there were exhaust fumes inside the vehicle. The engine warning light was illuminated. The vehicle was diagnosed by an independent mechanic and confirmed the failure was a defective charcoal canister for the evac system…
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The contact owns a 2006 Ford Expedition. The contact stated that while driving 35 MPH, the contact stated that there were exhaust fumes inside the vehicle. The engine warning light was illuminated. The vehicle was diagnosed by an independent mechanic and confirmed the failure was a defective charcoal canister for the evac system. The vehicle had not been repaired. The manufacturer was made aware of the failure however, the part was not available. The failure mileage was approximately 70,000.
NHTSA ODI #11539771
163,000 miles · Aug 9, 2014
Air BagsFuel System, GasolineVehicle Speed ControlCrashInjury
AS I WAS SLOWING DOWN AND MADE A RIGHT TURN INTO A PARKING SPACE, THE VEHICLE ACCELERATED ON ITS OWN, RUNNING OVER THE CONCRETE STOP AND THE CURVE. THE CAR CONTINUED TO ACCELERATE AND RAN HEAD ON INTO A TREE THAT WAS APPROXIMATELY 10 FEET AWAY FROM THE PARKING SPACE. THE DRIVER AIRBAG DID NOT DEPLOY. MY CAR WAS TOTALED AS A RE…
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AS I WAS SLOWING DOWN AND MADE A RIGHT TURN INTO A PARKING SPACE, THE VEHICLE ACCELERATED ON ITS OWN, RUNNING OVER THE CONCRETE STOP AND THE CURVE. THE CAR CONTINUED TO ACCELERATE AND RAN HEAD ON INTO A TREE THAT WAS APPROXIMATELY 10 FEET AWAY FROM THE PARKING SPACE. THE DRIVER AIRBAG DID NOT DEPLOY. MY CAR WAS TOTALED AS A RESULT OF THIS ACCIDENT. *TR
NHTSA ODI #10621042
111,400 miles · May 22, 2014
Fuel System, GasolineFire
LESS THAN 3 MINUTES AFTER CAR PARKED, FIRE DEVELOPED FROM TOP OF FUEL TANK AND IN 15 MINUTES, VEHICLE WAS DESTROYED. *TR
NHTSA ODI #10593339
116,000 miles · Apr 23, 2014
EngineFuel System, GasolinePower Train
WAS DRIVING DOWN OFF RAMP LOST ALL POWER TO THE VEHICLE, NO STEERING, NO BRAKES. I HAD MY 3 CHILDREN IN THE VEHICLE WITH ME AND THANKFULLY I WAS ABLE TO COST TO THE SHOULDER UNTIL HELP ARRIVED. EXTREMELY SCARY HAD IT HAPPEN 2 MINUTES EARLIER WOULD OF BEEN OFF THE RAMP AND INTO ONCOMING TRAFFIC! THIS IS UNACCEPTABLE!! MY MECHANIC…
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WAS DRIVING DOWN OFF RAMP LOST ALL POWER TO THE VEHICLE, NO STEERING, NO BRAKES. I HAD MY 3 CHILDREN IN THE VEHICLE WITH ME AND THANKFULLY I WAS ABLE TO COST TO THE SHOULDER UNTIL HELP ARRIVED. EXTREMELY SCARY HAD IT HAPPEN 2 MINUTES EARLIER WOULD OF BEEN OFF THE RAMP AND INTO ONCOMING TRAFFIC! THIS IS UNACCEPTABLE!! MY MECHANIC SAYS IT'S THE FUEL PUMP, AND JUST THE PART IS 500 DOLLARS?!? THIS COULD OF ENDED VERY BADLY AND I HAVE HAD NOTHING BUT ISSUES WITH THIS PIECE OF JUNK. THE PAINT IS PEELING OFF, LOOKS LIKE NO PRIMER OR SEALER WAS USED IT LITERALLY IS FLAKING OFF ON THE HOOD AND REAR GATE RIGHT WHERE YOU WOULD PUT YOUR HANDS TO OPEN IT. IN THE MANUAL IN VERY SMALL PRINT IT SAYS THE OIL FROM YOUR FINGERS MAY CAUSE PAINT TO CORRODE, ARE YOU KIDDING ME??? YOUR NOT SUPPOSED TO OPEN YOUR HOOD OR TAILGATE??? RIDICULOUS!! THIS VEHICLE IN MY OPINION IS A LEMON!! *TR
NHTSA ODI #10584466
84,600 miles · Apr 28, 2012
Fuel System, Gasoline
MY CUSTOMER CALLED TO INFORM ME THAT HE WAS SMELLING RAW FUEL INSIDE THE VEHICLE ON APRIL 13,2012. I TOLD HIM IT WAS PROBABLY A STUCK INJECTOR. BEING A FORD SENIOR MASTER CERTIFIED AUTO REPAIR TECHNICIAN/ASE MASTER CERTIFIED FOR FORD DEALERSHIPS FOR OVER 14 YEARS I WAS AWARE OF THE INJECTOR CONCERNS WITH THESE VEHICLES. I CHECKE…
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MY CUSTOMER CALLED TO INFORM ME THAT HE WAS SMELLING RAW FUEL INSIDE THE VEHICLE ON APRIL 13,2012. I TOLD HIM IT WAS PROBABLY A STUCK INJECTOR. BEING A FORD SENIOR MASTER CERTIFIED AUTO REPAIR TECHNICIAN/ASE MASTER CERTIFIED FOR FORD DEALERSHIPS FOR OVER 14 YEARS I WAS AWARE OF THE INJECTOR CONCERNS WITH THESE VEHICLES. I CHECKED THE ENGINE OIL TO FIND THAT IT WAS OVERFILLED A QUART AND SMELLED OF FUEL. MY DIAGNOSIS WAS CORRECT #2 INJECTOR WAS LEAKING BADLY. I REPLACED #2 INJECTOR AND CHANGED THE OIL,FOUND SMALL SHARDS OF RUST IN THE INJECTOR THAT COULD ONLY HAVE COME FROM THE FUEL RAIL AS THEY WERE TOO LARGE TO HAVE BY-PASSED THE FUEL FILTER. 2005 F SERIESEXPEDITIONS/NAVIGATORS HAD A RECALL ON INJECTORS AND THE 2006-2007 VEHICLES SHOULD HAVE HAD THE RECALL. THIS COULD BE A POTENTIAL FIRE HAZZARD CAUSING MAJOR ENGINE DAMAGE IF IT OCCURS AGAIN.RESEARCH ONLINE AND FOUND THAT THOUSANDS OF FORD EXPEDITION,LICOLN NAVIGATOR AND F-150-250 OWNERS HAVE HAD THE SAME PROBLEMS WITH INJECTORS. I AM ALSO AWARE OF A RECALL THAT WAS ON CERTAIN EXPEDITIONS AND NAVIGATORS FOR A NEW FUEL RAIL THAT WAS RUSTING INTERNALLY CAUSING THE SAME PROBLEMS BUT THE RECALL JUST CLAIMS THAT THE FUEL RAILS WERE "DEFECTIVE".FORD MOTOR COMPANY IS AWARE OF THESE CONCERNS AND REFUSES TO RESOLVE OR HELP ANY OWNERS OF THE AFFECTED VEHICLES OUTSIDE THE RECALL. IF THESE VEHICLES ARE ALLOWED TO CONTINUE TO OPERATE WITHOUT BEING PROPERLY REPAIRED EVENTUALLY SOMEONE IS GOING TO BE INJURED OR WORSE. I HAVE WITNESSED ENGINE EXPLOSIONS AND FIRES CAUSED BY LEAKING INJECTORS. THIS IS CLEARLY A MANUFACTURE DEFECT AND SHOULD BE ADRESSED BY FORD MOTOR COMPANY.I URGE ANY FORD OWNERS WITH THIS PROBLEM TO FILE A CLAIM WITH NHTSA AS WELL AS FORD MOTOR COMPANY SO THEY CAN RESOLVE THESE CONCERN BEFORE ANYONE IS HARMED.ALL MY CUSTOMER WANTS IS THE FUEL RAIL AND INJECTORS REPLACED. *TR
NHTSA ODI #10456764
59,000 miles · Jun 8, 2011
Fuel System, Gasoline
I WAS COMING ACROSS ARIZONA, INTERSTATE 10 IN MY 2006 EXPEDITION HEADING HOME TO SAN DIEGO WHEN MY "ENGINE FAILSAFE MODE" INDICATOR CAME ON, THE ENGINE WARNING LIGHT WAS ON AND SHUT THE ENGINE DOWN. THE ENGINE WARNING LIGHT NEVER WENT OFF UNTIL I TOOK IT TO A MECHANIC THE FOLLOWING MORNING. THE MECHANIC STATED THAT I NEED TO HAV…
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I WAS COMING ACROSS ARIZONA, INTERSTATE 10 IN MY 2006 EXPEDITION HEADING HOME TO SAN DIEGO WHEN MY "ENGINE FAILSAFE MODE" INDICATOR CAME ON, THE ENGINE WARNING LIGHT WAS ON AND SHUT THE ENGINE DOWN. THE ENGINE WARNING LIGHT NEVER WENT OFF UNTIL I TOOK IT TO A MECHANIC THE FOLLOWING MORNING. THE MECHANIC STATED THAT I NEED TO HAVE THE THROTTLE CLEANED OUT AND MAY NEED A NEW SENSOR FOR THE SIDE OF THE THROTTLE REPLACED. I HAVE 59K MILES ON MY VEHICLE AND HAVE THE MAINT. COMPLETED EVERY 4K TO 6K AND HAVE OWNED THIS VEHICLE FROM THE START. I HAD 2 MILES ON THE VEHICLE WHEN WE PURCHASED THIS VEHICLE IN OCT 2005. AFTER READING ABOUT THIS PROBLEM WITH OTHER OWNERS I THINK FORD SHOULD BE ABLE TO REPAIR OR REPLACE THE PROBLEM WITHOUT CHARGING THE CUSTOMER. THIS IS THE SECOND TIME THIS HAS HAPPENED TO ME. BOTH TIMES WE HAD THE CRUISE CONTROL TURNED ON. AFTER STOPPING IN THE MIDDLE PART OF ARIZONA ON THE SIDE OF THE ROAD, WE RESTARTED THE MOTOR AND MADE IT BACK HOME AFTER OUR VACATION. *TR
NHTSA ODI #10405638
125,000 miles · Apr 27, 2011
Fuel System, GasolineFire
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT WAS DRIVING APPROXIMATELY 55 MPH WHEN THE VEHICLE BEGAN TO DECELERATE INDEPENDENTLY. THE VEHICLE WAS MOVED FROM THE ROADWAY AND WHEN THE CONTAC EXITED, THERE WAS AN ABNORMAL BURNING ODOR AND BLACK SMOKE EMITTING FROM THE TAILPIPE. THE POLICE WERE DISPATCHED AND WHEN THEY A…
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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT WAS DRIVING APPROXIMATELY 55 MPH WHEN THE VEHICLE BEGAN TO DECELERATE INDEPENDENTLY. THE VEHICLE WAS MOVED FROM THE ROADWAY AND WHEN THE CONTAC EXITED, THERE WAS AN ABNORMAL BURNING ODOR AND BLACK SMOKE EMITTING FROM THE TAILPIPE. THE POLICE WERE DISPATCHED AND WHEN THEY ARRIVED AND OPENED THE REAR DRIVER SIDE DOOR, THICK BLACK SMOKE WAS POURING OUT FROM THE INSIDE OF THE VEHICLE. THERE WERE ALSO FLAMES FROM THE INTERIOR AND UNDER THE FRAME. THE FIRE WAS EXTINGUISHED BY THE LOCAL FIRE DEPARTMENT. THE FIRE CHIEF ADVISED THAT THERE WAS A HOLE IN THE FUEL LINE AND AN ELECTRICAL PROBLEM THAT COULD HAVE CAUSED THE FIRE BUT THE RESULTS WERE INCONCLUSIVE. THE VEHICLE WAS TOWED BY THE CONTACTS INSURANCE COMPANY. THE INSURANCE ADJUSTER INFORMED THE CONTACT THAT THE VEHICLE WAS DESTROYED AND THEY WERE UNABLE TO DETERMINE THE CAUSE OF THE FIRE. THERE WERE NO INJURIES. THE MANUFACTURER WAS NOT CONTACTED TO REPORT THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 125,000.
NHTSA ODI #10397988
81,200 miles · Apr 24, 2011
Engine And Engine CoolingFuel System, Gasoline
1/8/09 WHILE DRIVING AT 65 MPH ON HIGHWAY VEHICLE'S "ENGINE FAIL SAFE MODE" ALARM SOUNDED & MESSAGE FLASHED ON PANEL. VEHICLE IMMEDIATELY LOST POWER. I WAS ABLE TO COAST TO SHOULDER OF ROAD. TURNED OFF VEHICLE, RESTARTED AND WAS ABLE TO DRIVE APPROXIMATELY 1 1/2 MILES. I WAS IN TURN LANE, STARTED TO TURN LEFT, ALARM SOUNDED,…
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1/8/09 WHILE DRIVING AT 65 MPH ON HIGHWAY VEHICLE'S "ENGINE FAIL SAFE MODE" ALARM SOUNDED & MESSAGE FLASHED ON PANEL. VEHICLE IMMEDIATELY LOST POWER. I WAS ABLE TO COAST TO SHOULDER OF ROAD. TURNED OFF VEHICLE, RESTARTED AND WAS ABLE TO DRIVE APPROXIMATELY 1 1/2 MILES. I WAS IN TURN LANE, STARTED TO TURN LEFT, ALARM SOUNDED, MESSAGE FLASHED AND ALL POWER WAS GONE. I QUICKLY TURNED VEHICLE OFF AND BACK ON TO TRY AND GET OUT OF PATH OF ONCOMING TRACTOR TRAILER. I WAS ABLE TO GET JUST OFF ROADWAY AFTER 15 MINS STARTED VEHICLE, DROVE 4 MILES FAILED AGAIN. IT WAS TOWED TO MECHANIC. AFTER CALLS TO FORD AND FURTHER TESTING THE ELECTRONIC THROTTLE BODY ASSEMBLY WAS REPLACED. ON 1/30/10, 35 MILES FROM HOME, DRIVING ON HIGHWAY AT 55 MPH WHEN "ENGINE FAIL SAFE MODE" ALARM SOUNDED & MESSAGE FLASHED ON PANEL. AGAIN I WAS ABLE TO SAFELY PULL TO SHOULDER OF ROAD TO AVOID ACCIDENT. I CALLED FORD DEALER LOCATED IN THAT TOWN, HAD VEHICLE AGAIN TOWED TO SHOP AND THEY REPLACED AN ADDITIONAL PART. I CALLED FORD AFTER 2ND EVENT, I WAS TOLD BY FORD THAT THEY ARE AWARE OF THE PROBLEM, HOWEVER SINCE THEY DON'T HAVE A SOLUTION TO IT THEY DO NOT HAVE A RECALL ON THIS. ON 4/20/11 WHILE DRIVING HOME FROM WORK ON HIGHWAY AT 60 MPH THE "ENGINE FAIL SAFE MODE" ALARM & MESSAGE FLASHING ON PANEL. I WAS IN FAR RIGHT LANE SO AGAIN WAS ABLE TO COAST TO SHOULDER BEFORE STEERING LOCKED FROM NO POWER. IF I HAD BEEN IN LEFT LANE I WOULD NOT HAVE BEEN ABLE TO GET OFF ROADWAY. (ON 4/19/11 I HAD VEHICLE INSPECTED, IN NYS, NO CODES WERE ON THIS VEHICLE). TOWED TO SHOP, AFTER RUNNING TESTS AND CALLS TO FORD THEY HAVE AGAIN REPLACED THE ELECTRONIC THROTTLE BODY ASSEMBLY AS IT HAD FAILED. STILL NO RECALL. THIS IS EXTREME SAFETY ISSUE. I HAVE AVOIDED ACCIDENTS 3 TIMES, IF I HAD BEEN IN LEFT LANES I WOULD NOT HAVE BEEN SO LUCKY. THIS HAPPENS WITH NO ADVANCE WARNING. FORD KNOWS THERE IS A PROBLEM.
NHTSA ODI #10397771
76,170 miles · Jan 6, 2011
Electrical SystemFuel System, Gasoline
MY WIFE WAS DRIVING HER 2006 FORD EXPEDITION DOWN A BUSY ROAD AT A SPEED OF ABOUT 40 MPH. SHE WAS DRIVING WITH ANOTHER FRIEND AND OUR 2 CHILDREN (18 MONTHS AND 1 WEEK!) A WRENCH SYMBOL WARNING LIGHT CAME ON AND THE VEHICLE SHUT DOWN. SHE PUT ON HER HAZARDS AND WAS ABLE TO SAFELY COME TO A STOP. SHE TURNED THE IGNITION KEY TO THE…
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MY WIFE WAS DRIVING HER 2006 FORD EXPEDITION DOWN A BUSY ROAD AT A SPEED OF ABOUT 40 MPH. SHE WAS DRIVING WITH ANOTHER FRIEND AND OUR 2 CHILDREN (18 MONTHS AND 1 WEEK!) A WRENCH SYMBOL WARNING LIGHT CAME ON AND THE VEHICLE SHUT DOWN. SHE PUT ON HER HAZARDS AND WAS ABLE TO SAFELY COME TO A STOP. SHE TURNED THE IGNITION KEY TO THE OFF POSITION AND THEN WAS ABLE TO START THE ENGINE AGAIN. AFTER TALKING TO A MECHANIC AND DOING INTERNET RESEARCH I FOUND THIS IS A VERY COMMON PROBLEM WHICH CONSISTS OF THE ELECTRONIC CONTROL OF THE THROTTLE. THE FIX IS UPWARDS OF $500; SO A RECALL OF SOMETHING THAT EXPENSIVE CAN EASILY BE BRUSHED UNDER THE TABLE BY FORD. THIS PROBLEM NEEDS TO BE ADDRESSED BY FORD. IF MORE VEHICLES KEEP SHUTTING DOWN ON THEIR OWN SOMEONE WILL SOON BE INJURED OR KILLED. *TR
NHTSA ODI #10374970
65,000 miles · Jun 15, 2010
Engine And Engine CoolingFuel System, Gasoline
TL*THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING THE CHECK ENGINE LIGHT ILLUMINATED. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALERSHIP WHERE THE CONTACT WAS INFORMED THAT THE FUEL INJECTORS WERE STUCK OPEN AND FLOODED THE ENGINE. THE DEALER ALSO STATED THAT BOTH CATALYTIC CONVERTERS WERE RUINED A…
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TL*THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING THE CHECK ENGINE LIGHT ILLUMINATED. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALERSHIP WHERE THE CONTACT WAS INFORMED THAT THE FUEL INJECTORS WERE STUCK OPEN AND FLOODED THE ENGINE. THE DEALER ALSO STATED THAT BOTH CATALYTIC CONVERTERS WERE RUINED AND NEEDED TO BE REPLACED, AND THE ENGINE WAS POSSIBLY DAMAGED. THE CONTACT STATED THAT THERE WAS A RECALL RELATED TO THE FAILURE FOR PREVIOUS MODEL YEARS AND WARRANTIES WERE EXTENDED AS A RESULT. THE CONTACT CALLED THE MANUFACTURER WHO STATED THAT THEY WOULD NOT EXTEND THE WARRANTY ON THE VEHICLE. THE CONTACT FILED A COMPLAINT. THE CURRENT AND FAILURE MILEAGES WERE APPROXIMATELY 65,000. UPDATED 11/19/10. *LJ UPDATED 10/27/10. *LJ THE CONSUMER STATED A NEW ENGINE WAS PUT IN THE VEHICLE. HOWEVER, HE CONTINUED TO EXPERIENCE PROBLEMS. THE DEALER STATED THE #6 CYLINDER HAD COMPRESSED CAUSING THE PISTON TO STOP A HALF INCH FROM THE TOP WHICH CAUSED THE VEHICLE TO SHUT DOWN. UPDATED 11/24/10
NHTSA ODI #10336418
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