NHTSA owner reports · September 18, 2026 snapshot.
Power Train complaints
22 reportsClear category filter222,000 miles · Apr 21, 2023
Air BagsElectrical SystemPower TrainCrashInjury
The contact owns a 2006 Ford Expedition. The contact stated that while driving at a low rate of speed, the vehicle would independently accelerate upon depression of the accelerator pedal without warning. During a recent failure, the contact crashed into a fence as part of the fence had become wedged underneath the vehicle. Afte…
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The contact owns a 2006 Ford Expedition. The contact stated that while driving at a low rate of speed, the vehicle would independently accelerate upon depression of the accelerator pedal without warning. During a recent failure, the contact crashed into a fence as part of the fence had become wedged underneath the vehicle. After placing the vehicle into park and exiting the vehicle, the wheels continued to move. The air bags did not deploy upon impact. Despite minor soreness to his neck, no medial attention was required. A police report was not filed. Despite the failure, the contact managed to restart the vehicle and safely to his destination. The fence sustained severe damage as a result of the failure. The dealer nor the manufacturer had yet to be notified of the failure. The vehicle had yet to be diagnosed or repaired. The failure mileage was approximately 220,000.
NHTSA ODI #11518263
160,000 miles · Feb 27, 2018
Fuel/propulsion SystemPower Train
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. WHILE DRIVING VARIOUS SPEEDS, THE VEHICLE STALLED WITHOUT WARNING. THE CONTACT STATED THAT THE "FAIL SAFE MODE" INDICATOR DISPLAYED. HERTRICH FORD IN MILFORD, DELAWARE WAS MADE AWARE OF THE FAILURE AND REPLACED THE THROTTLE BODY AND THE DRIVER'S SIDE FUEL MODULE. THE MANUFACTURER WAS …
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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. WHILE DRIVING VARIOUS SPEEDS, THE VEHICLE STALLED WITHOUT WARNING. THE CONTACT STATED THAT THE "FAIL SAFE MODE" INDICATOR DISPLAYED. HERTRICH FORD IN MILFORD, DELAWARE WAS MADE AWARE OF THE FAILURE AND REPLACED THE THROTTLE BODY AND THE DRIVER'S SIDE FUEL MODULE. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND REFERRED THE CONTACT TO NHTSA. THE FAILURE MILEAGE WAS APPROXIMATELY 160,000.
NHTSA ODI #11075280
80,000 miles · Aug 5, 2017
Power TrainStructure
CORROSION PROBLEMS IN MANY DIFFERENT PARTS OF THE VEHICLE.
NHTSA ODI #11013028
107,000 miles · Oct 17, 2016
Power Train
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. WHILE DRIVING 45 MPH, THE OSC WARNING INDICATOR ILLUMINATED ON THE INSTRUMENT PANEL. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHERE IT WAS DIAGNOSED THAT THE TRANSMISSION TORQUE CONVERTER FAILED AND NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED; HOWEVER, THE FAILURE RECURRED…
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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. WHILE DRIVING 45 MPH, THE OSC WARNING INDICATOR ILLUMINATED ON THE INSTRUMENT PANEL. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHERE IT WAS DIAGNOSED THAT THE TRANSMISSION TORQUE CONVERTER FAILED AND NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED; HOWEVER, THE FAILURE RECURRED. THE VEHICLE WAS TAKEN TO A TRANSMISSION SPECIALIST WHERE IT WAS DIAGNOSED THAT SEVERAL COMPONENTS IN THE TRANSMISSION FAILED AND NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS APPROXIMATELY 107,000.
NHTSA ODI #10916436
86,900 miles · Jun 6, 2016
EnginePower TrainSteering
MY 2006 FORD EXPEDITION'S "ENGINE FAILSAFE MODE" INITIATED AND ALERTED ME WHILE I WAS OPERATING THE VEHICLE, WHICH RESULTED IN THE VEHICLE SHUTTING DOWN COMPLETELY AND LOSING ALL POWER. MY MAIN ISSUE/CONCERN WITH THIS IS THAT I LOST STEERING AND A SIGNIFICANT AMOUNT OF BRAKING POWER. FORTUNATELY, I WAS ON A SIDE ROAD AND WAS ABL…
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MY 2006 FORD EXPEDITION'S "ENGINE FAILSAFE MODE" INITIATED AND ALERTED ME WHILE I WAS OPERATING THE VEHICLE, WHICH RESULTED IN THE VEHICLE SHUTTING DOWN COMPLETELY AND LOSING ALL POWER. MY MAIN ISSUE/CONCERN WITH THIS IS THAT I LOST STEERING AND A SIGNIFICANT AMOUNT OF BRAKING POWER. FORTUNATELY, I WAS ON A SIDE ROAD AND WAS ABLE TO SAFELY PULL OVER OUT OF HARM'S WAY. THE VEHICLE WAS ABLE TO START A COUPLE OF TRIES LATER, AND I WAS ABLE TO GET THE VEHICLE INTO A SERVICE SHOP SAFELY, WHICH WAS OVER AN HOUR AWAY. I CANNOT HELP BUT BE GRATEFUL FOR GETTING HOME SAFELY, BUT AM VERY CONCERNED ABOUT THESE VEHICLES EXPERIENCING SUCH ISSUES AS THEY TRAVERSE MAJOR THOROUGHFARES, ESPECIALLY ON A HIGHWAY TRAVELING AROUND 70MPH. THIS POTENTIALLY POSED VERY IMPACTFUL CONSEQUENCES AND PUTS MYSELF, FRIENDS/FAMILY TRAVELING WITH ME, AND OTHER MOTORISTS.
NHTSA ODI #10872668
141,000 miles · Oct 23, 2015
EnginePower Train
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. WHILE DRIVING 45 MPH, THE VEHICLE LOST POWER. WHEN THE ACCELERATOR PEDAL WAS DEPRESSED, THE VEHICLE FAILED TO ACCELERATE AND THE RPMS INCREASED. THE CHECK ENGINE AND SERVICE VEHICLE SOON WARNING LIGHTS ILLUMINATED. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE FAILURE RECURRED ON NUM…
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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. WHILE DRIVING 45 MPH, THE VEHICLE LOST POWER. WHEN THE ACCELERATOR PEDAL WAS DEPRESSED, THE VEHICLE FAILED TO ACCELERATE AND THE RPMS INCREASED. THE CHECK ENGINE AND SERVICE VEHICLE SOON WARNING LIGHTS ILLUMINATED. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE FAILURE RECURRED ON NUMEROUS OCCASIONS. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 141,000.
NHTSA ODI #10785496
134,587 miles · Oct 20, 2015
Power Train
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. WHILE DRIVING AT 60 MPH, THE VEHICLE STALLED AND THE CHECK ENGINE WARNING LIGHT ILLUMINATED. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHERE IT WAS DIAGNOSED THAT THE TRANSMISSION FAILED AND THE SECOND GEAR FAILED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEA…
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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. WHILE DRIVING AT 60 MPH, THE VEHICLE STALLED AND THE CHECK ENGINE WARNING LIGHT ILLUMINATED. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHERE IT WAS DIAGNOSED THAT THE TRANSMISSION FAILED AND THE SECOND GEAR FAILED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 134,587.
NHTSA ODI #10783799
100,000 miles · Dec 19, 2014
EnginePower Train
AS I AM DRIVING DOWN THE ROAD I LOSE POWER AND DEACCELERATE AND GO INTO FAIL SAFE MODE. THE LITTLE WRENCH LIGHT COMES ON THE DASH. THEN THE ENGINE CUTS OFF COMPLETELY. THIS HAS HAPPENED AT MULTIPLE SPEEDS. IT IS EXTREMELY DANGEROUS! ONCE I TURN THE KEY OFF I RESTART THE ENGINE AND IT MAY NOT HAPPEN AGAIN FOR A MONTH. I REPLACED …
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AS I AM DRIVING DOWN THE ROAD I LOSE POWER AND DEACCELERATE AND GO INTO FAIL SAFE MODE. THE LITTLE WRENCH LIGHT COMES ON THE DASH. THEN THE ENGINE CUTS OFF COMPLETELY. THIS HAS HAPPENED AT MULTIPLE SPEEDS. IT IS EXTREMELY DANGEROUS! ONCE I TURN THE KEY OFF I RESTART THE ENGINE AND IT MAY NOT HAPPEN AGAIN FOR A MONTH. I REPLACED THE THROTTLE POSITION SENSOR AND IT DID NOT DO THIS FOR ABOUT A YEAR, NOW IT IS STARTING AGAIN AND IT HAS HAPPENED 5 TIMES IN THE LAST 3 MONTHS. IT HAS HAPPENED AT 65MPH, 40MPH, 25MPH, 55MPH, 30 MPH. THERE IS NO PATTERN. I HAVE BEEN LUCKY THAT I HAVE BEEN ABLE TO PULL OVER TO THE SIDE OF THE ROAD OR TURN INTO A PARKING LOT EACH TIME THIS HAPPENS, IT SCARES ME! I HAVE READ MULTIPLE ACCOUNTS OF THIS HAPPENING ONLINE TO THE 2006 AND WONDER WHY IT HAS NOT BEEN RECALLED IF THERE ARE SO MANY PROBLEMS WITH IT. I HAVE TAKEN IT TO FORD TWICE AND BC THE LIGHT DOES NOT STAY ON AND IT IS NOT HAPPENING WHEN I BRING IT TO THEM THEY TELL ME THERE IS NOTHING THEY CAN DO. *TR
NHTSA ODI #10667242
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
110 miles · Apr 17, 2014
Power Train
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT THE OVER-DRIVE FUNCTION WOULD DISENGAGE INDEPENDENTLY. CAUSING THE VEHICLE TO DECELERATE AND THEN RETURN TO NORMAL SPEED. THE VEHICLE WAS TAKEN TO THE DEALER WHERE THE TECHNICIAN DIAGNOSED THAT THE CRUISE CONTROL WAS ALTERING THE TRANSMISSION. THE VEHICLE WAS …
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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT THE OVER-DRIVE FUNCTION WOULD DISENGAGE INDEPENDENTLY. CAUSING THE VEHICLE TO DECELERATE AND THEN RETURN TO NORMAL SPEED. THE VEHICLE WAS TAKEN TO THE DEALER WHERE THE TECHNICIAN DIAGNOSED THAT THE CRUISE CONTROL WAS ALTERING THE TRANSMISSION. THE VEHICLE WAS REPAIRED BUT THE CONTACT WAS NOT ADVISED OF THE SPECIFIC REPAIRS. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 110 AND THE CURRENT MILEAGE WAS 98,421.
NHTSA ODI #10583376
NHTSA investigations
1PE08070 · Steel Wheel Fracture
Opened Dec 9, 2008 · Closed Apr 15, 2009
Status: closed (inferred from source dates) · Wheels; Wheels:rim
FORD SPECIAL SERVICE VEHICLE (SSV) EXPEDITIONS USE A STEEL FULL FACE WHEEL DESIGN SIMILAR TO THAT INVESTIGATED IN PE03009, RQ04007, EA04034 (CROWN VICTORIA POLICE INTERCEPTOR) AND PE03026 (GM PICKUPS AND SUVS).A TOTAL OF 8,251 SSVS (2.2% OF TOTAL PRODUCTION) WERE PRODUCED WITHIN MODEL YEARS 2004-2006 AND SOLD PRIMARILY FOR USE BY STATE, FEDERAL, AND MUNICIPAL LAW ENFORCEMENT (LE) AGENCIES.FORD STIPULATES THAT THE SUBJECT VEHICLES ARE NOT SUITABLE FOR HIGH SPEED OR PURSUIT OPERATIONS AND ALSO IDENTIFIED A 2004 NATIONAL INSTITUTE FOR JUSTICE VEHICLE EVALUATION REPORT WHICH ALSO ACKNOWLEDGES THIS LIMITATION. THE FULL FACE WHEEL IS FABRICATED FROM TWO PIECES: A STAMPED OUTER WHEEL DISC AND A FORMED RIM.THE TWO PIECES, WHICH TOGETHER COMPRISE THE OUTER BEAD SEAT, ARE JOINED TOGETHER WITH A CIRCUMFERENTIAL WELD.A CYCLIC BENDING MOMENT OCCURS IN THE OUTER BEAD SEAT AREA AS THE WHEEL ROTATES, RESULTING IN FATIGUE STRESSES IN THE WELD'S HEAT AFFECTED ZONE THAT CAN LEAD TO FRACTURING (CRACKING) OF THE RIM MATERIAL.BECAUSE THE FAILURE OCCURS UNDER THE OUTBOARD TIRE BEAD, AIR LEAKAGE MAY NOT READILY OCCUR WHEN THE RIM CRACKS, DEPENDENT ON HOW WELL THE BEAD SEALS ON THE RIM.IF MULTIPLE CRACKS GROW UNDETECTED AND SUDDENLY JOIN INTO A SINGLE LARGE CRACK, THE WHEEL'S STRUCTURE CAN BECOME COMPROMISED LEADING TO RAPID AIR LOSS.A RAPID AIR LOSS, ESPECIALLY AT HIGHER SPEED, MAY LEAD TO A CRASH. FORD RESPONDED TO ODI'S JANUARY 5, 2009 INFORMATION REQUEST (IR) ON FEBRUARY 24.FORD'S RESPONSE ACKNOWLEDGES A NUMBER OF WHEEL FRACTURES ON THE SSVS.HOWEVER, BASED ON ITS ASSESSMENT OF THE PERTINENT FACTORS, IT CONCLUDES THAT THE CONDITION DOES NOT REPRESENT AN UNREASONABLE RISK TO SAFETY.THE LACK OF REPORTS OF RAPID AIR LOSS, NO ALLEGED CRASHES, AND THEIR ASSESSMENT THAT A CRACKED WHEEL CAN BE DETECTED THROUGH SLOW, REPEATED AIR LOSS OR VIBRATION, WERE THE BASES FOR FORD'S CONCLUSION.FORD DISCUSSES THE RESULTS OF A STUDY IT PERFORMED ON WHEELS RETURNED FROM LE FIELD USE, DESIGN REVISIONS IT MADE TO THE SUBJECT WHEEL, AND THE OUTCOME OF DURABILITY TESTING IT CONDUCTED ON THE OLD AND NEW WHEEL DESIGNS. THE COUNTS SHOWN ABOVE INCLUDE A DUPLICATE ODI AND FORD REPORT; THE FORD COUNTS ARE UNIQUE VEHICLES ALLEGING WHEEL FRACTURE(S).SOME WARRANTY CLAIMS INVOLVED MORE THAN ONE WHEEL REPLACEMENT.ALTHOUGH THE SUBJECT VEHICLES HAVE BEEN IN SERVICE FOR A LONGER PERIOD OF TIME THAN VEHICLES INVESTIGATED IN THE PREVIOUS INVESTIGATIONS OF TWO-PIECE WHEEL FRACTURE, ODI DID NOT IDENTIFY ANY ALLEGATIONS OF CRASHES, RAPID AIR LOSS EVENTS DUE TO WHEEL FRACTURES OR ALLEGATIONS OF EFFECTS ON VEHICLE CONTROL OR STABILITY, AS WERE THE CASES IN PAST INVESTIGATIONS WHERE SAFETY RECALLS WERE CONDUCTED TO REPLACE AFFECTED WHEELS.THE AGENCY AGREES THAT THE SSV IS NOT SUITABLE FOR PURSUIT OR HIGH SPEED USAGE, REDUCING THE POTENTIAL FOR CRASHES OR LOSS OF CONTROL INCIDENTS TO BE CAUSED BY THE ALLEGED DEFECT. FORD IMPLEMENTED A 'SHOT PEENING' PROCESS IN JUNE 2006 WHICH REDUCED THE WHEEL'S SURFACE STRESS AND SIGNIFICANTLY IMPROVED ITS DURABILITY, AND ODI IS UNAWARE OF ANY FAILURES OF SHOT PEENED WHEELS (SERVICE PART NUMBER 7L1Z-1015-B).FORD'S TESTING SHOWED A SLIGHTLY REDUCED DURABILITY FOR THE NON-SHOT PEENED WHEELS WHEN 'LT' INSTEAD OF FORD APPROVED 'P' METRIC TYPE TIRES ARE USED. A SAFETY-RELATED DEFECT HAS NOT BEEN IDENTIFIED AT THIS TIME AND FURTHER USE OF AGENCY RESOURCES DOES NOT APPEAR TO BE WARRANTED.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST.THE AGENCY WILL TAKE FURTHER ACTION IF WARRANTED BY FURTHER C
Additional source detail variants (2)
Wheels
FORD SPECIAL SERVICE VEHICLE (SSV) EXPEDITIONS USE A STEEL FULL FACE WHEEL DESIGN SIMILAR TO THAT INVESTIGATED IN PE03009, RQ04007, EA04034 (CROWN VICTORIA POLICE INTERCEPTOR) AND PE03026 (GM PICKUPS AND SUVS).A TOTAL OF 8,251 SSVS (2.2% OF TOTAL PRODUCTION) WERE PRODUCED WITHIN MODEL YEARS 2004-2006 AND SOLD PRIMARILY FOR USE BY STATE, FEDERAL, AND MUNICIPAL LAW ENFORCEMENT (LE) AGENCIES.FORD STIPULATES THAT THE SUBJECT VEHICLES ARE NOT SUITABLE FOR HIGH SPEED OR PURSUIT OPERATIONS AND ALSO IDENTIFIED A 2004 NATIONAL INSTITUTE FOR JUSTICE VEHICLE EVALUATION REPORT WHICH ALSO ACKNOWLEDGES THIS LIMITATION. THE FULL FACE WHEEL IS FABRICATED FROM TWO PIECES: A STAMPED OUTER WHEEL DISC AND A FORMED RIM.THE TWO PIECES, WHICH TOGETHER COMPRISE THE OUTER BEAD SEAT, ARE JOINED TOGETHER WITH A CIRCUMFERENTIAL WELD.A CYCLIC BENDING MOMENT OCCURS IN THE OUTER BEAD SEAT AREA AS THE WHEEL ROTATES, RESULTING IN FATIGUE STRESSES IN THE WELD'S HEAT AFFECTED ZONE THAT CAN LEAD TO FRACTURING (CRACKING) OF THE RIM MATERIAL.BECAUSE THE FAILURE OCCURS UNDER THE OUTBOARD TIRE BEAD, AIR LEAKAGE MAY NOT READILY OCCUR WHEN THE RIM CRACKS, DEPENDENT ON HOW WELL THE BEAD SEALS ON THE RIM.IF MULTIPLE CRACKS GROW UNDETECTED AND SUDDENLY JOIN INTO A SINGLE LARGE CRACK, THE WHEEL'S STRUCTURE CAN BECOME COMPROMISED LEADING TO RAPID AIR LOSS.A RAPID AIR LOSS, ESPECIALLY AT HIGHER SPEED, MAY LEAD TO A CRASH. FORD RESPONDED TO ODI'S JANUARY 5, 2009 INFORMATION REQUEST (IR) ON FEBRUARY 24.FORD'S RESPONSE ACKNOWLEDGES A NUMBER OF WHEEL FRACTURES ON THE SSVS.HOWEVER, BASED ON ITS ASSESSMENT OF THE PERTINENT FACTORS, IT CONCLUDES THAT THE CONDITION DOES NOT REPRESENT AN UNREASONABLE RISK TO SAFETY.THE LACK OF REPORTS OF RAPID AIR LOSS, NO ALLEGED CRASHES, AND THEIR ASSESSMENT THAT A CRACKED WHEEL CAN BE DETECTED THROUGH SLOW, REPEATED AIR LOSS OR VIBRATION, WERE THE BASES FOR FORD'S CONCLUSION.FORD DISCUSSES THE RESULTS OF A STUDY IT PERFORMED ON WHEELS RETURNED FROM LE FIELD USE, DESIGN REVISIONS IT MADE TO THE SUBJECT WHEEL, AND THE OUTCOME OF DURABILITY TESTING IT CONDUCTED ON THE OLD AND NEW WHEEL DESIGNS. THE COUNTS SHOWN ABOVE INCLUDE A DUPLICATE ODI AND FORD REPORT; THE FORD COUNTS ARE UNIQUE VEHICLES ALLEGING WHEEL FRACTURE(S).SOME WARRANTY CLAIMS INVOLVED MORE THAN ONE WHEEL REPLACEMENT.ALTHOUGH THE SUBJECT VEHICLES HAVE BEEN IN SERVICE FOR A LONGER PERIOD OF TIME THAN VEHICLES INVESTIGATED IN THE PREVIOUS INVESTIGATIONS OF TWO-PIECE WHEEL FRACTURE, ODI DID NOT IDENTIFY ANY ALLEGATIONS OF CRASHES, RAPID AIR LOSS EVENTS DUE TO WHEEL FRACTURES OR ALLEGATIONS OF EFFECTS ON VEHICLE CONTROL OR STABILITY, AS WERE THE CASES IN PAST INVESTIGATIONS WHERE SAFETY RECALLS WERE CONDUCTED TO REPLACE AFFECTED WHEELS.THE AGENCY AGREES THAT THE SSV IS NOT SUITABLE FOR PURSUIT OR HIGH SPEED USAGE, REDUCING THE POTENTIAL FOR CRASHES OR LOSS OF CONTROL INCIDENTS TO BE CAUSED BY THE ALLEGED DEFECT. FORD IMPLEMENTED A 'SHOT PEENING' PROCESS IN JUNE 2006 WHICH REDUCED THE WHEEL'S SURFACE STRESS AND SIGNIFICANTLY IMPROVED ITS DURABILITY, AND ODI IS UNAWARE OF ANY FAILURES OF SHOT PEENED WHEELS (SERVICE PART NUMBER 7L1Z-1015-B).FORD'S TESTING SHOWED A SLIGHTLY REDUCED DURABILITY FOR THE NON-SHOT PEENED WHEELS WHEN 'LT' INSTEAD OF FORD APPROVED 'P' METRIC TYPE TIRES ARE USED. A SAFETY-RELATED DEFECT HAS NOT BEEN IDENTIFIED AT THIS TIME AND FURTHER USE OF AGENCY RESOURCES DOES NOT APPEAR TO BE WARRANTED.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST.THE AGENCY WILL TAKE FURTHER ACTION IF WARRANTED BY FURTHER C
Wheels:rim
FORD SPECIAL SERVICE VEHICLE (SSV) EXPEDITIONS USE A STEEL FULL FACE WHEEL DESIGN SIMILAR TO THAT INVESTIGATED IN PE03009, RQ04007, EA04034 (CROWN VICTORIA POLICE INTERCEPTOR) AND PE03026 (GM PICKUPS AND SUVS).A TOTAL OF 8,251 SSVS (2.2% OF TOTAL PRODUCTION) WERE PRODUCED WITHIN MODEL YEARS 2004-2006 AND SOLD PRIMARILY FOR USE BY STATE, FEDERAL, AND MUNICIPAL LAW ENFORCEMENT (LE) AGENCIES.FORD STIPULATES THAT THE SUBJECT VEHICLES ARE NOT SUITABLE FOR HIGH SPEED OR PURSUIT OPERATIONS AND ALSO IDENTIFIED A 2004 NATIONAL INSTITUTE FOR JUSTICE VEHICLE EVALUATION REPORT WHICH ALSO ACKNOWLEDGES THIS LIMITATION. THE FULL FACE WHEEL IS FABRICATED FROM TWO PIECES: A STAMPED OUTER WHEEL DISC AND A FORMED RIM.THE TWO PIECES, WHICH TOGETHER COMPRISE THE OUTER BEAD SEAT, ARE JOINED TOGETHER WITH A CIRCUMFERENTIAL WELD.A CYCLIC BENDING MOMENT OCCURS IN THE OUTER BEAD SEAT AREA AS THE WHEEL ROTATES, RESULTING IN FATIGUE STRESSES IN THE WELD'S HEAT AFFECTED ZONE THAT CAN LEAD TO FRACTURING (CRACKING) OF THE RIM MATERIAL.BECAUSE THE FAILURE OCCURS UNDER THE OUTBOARD TIRE BEAD, AIR LEAKAGE MAY NOT READILY OCCUR WHEN THE RIM CRACKS, DEPENDENT ON HOW WELL THE BEAD SEALS ON THE RIM.IF MULTIPLE CRACKS GROW UNDETECTED AND SUDDENLY JOIN INTO A SINGLE LARGE CRACK, THE WHEEL'S STRUCTURE CAN BECOME COMPROMISED LEADING TO RAPID AIR LOSS.A RAPID AIR LOSS, ESPECIALLY AT HIGHER SPEED, MAY LEAD TO A CRASH. FORD RESPONDED TO ODI'S JANUARY 5, 2009 INFORMATION REQUEST (IR) ON FEBRUARY 24.FORD'S RESPONSE ACKNOWLEDGES A NUMBER OF WHEEL FRACTURES ON THE SSVS.HOWEVER, BASED ON ITS ASSESSMENT OF THE PERTINENT FACTORS, IT CONCLUDES THAT THE CONDITION DOES NOT REPRESENT AN UNREASONABLE RISK TO SAFETY.THE LACK OF REPORTS OF RAPID AIR LOSS, NO ALLEGED CRASHES, AND THEIR ASSESSMENT THAT A CRACKED WHEEL CAN BE DETECTED THROUGH SLOW, REPEATED AIR LOSS OR VIBRATION, WERE THE BASES FOR FORD'S CONCLUSION.FORD DISCUSSES THE RESULTS OF A STUDY IT PERFORMED ON WHEELS RETURNED FROM LE FIELD USE, DESIGN REVISIONS IT MADE TO THE SUBJECT WHEEL, AND THE OUTCOME OF DURABILITY TESTING IT CONDUCTED ON THE OLD AND NEW WHEEL DESIGNS. THE COUNTS SHOWN ABOVE INCLUDE A DUPLICATE ODI AND FORD REPORT; THE FORD COUNTS ARE UNIQUE VEHICLES ALLEGING WHEEL FRACTURE(S).SOME WARRANTY CLAIMS INVOLVED MORE THAN ONE WHEEL REPLACEMENT.ALTHOUGH THE SUBJECT VEHICLES HAVE BEEN IN SERVICE FOR A LONGER PERIOD OF TIME THAN VEHICLES INVESTIGATED IN THE PREVIOUS INVESTIGATIONS OF TWO-PIECE WHEEL FRACTURE, ODI DID NOT IDENTIFY ANY ALLEGATIONS OF CRASHES, RAPID AIR LOSS EVENTS DUE TO WHEEL FRACTURES OR ALLEGATIONS OF EFFECTS ON VEHICLE CONTROL OR STABILITY, AS WERE THE CASES IN PAST INVESTIGATIONS WHERE SAFETY RECALLS WERE CONDUCTED TO REPLACE AFFECTED WHEELS.THE AGENCY AGREES THAT THE SSV IS NOT SUITABLE FOR PURSUIT OR HIGH SPEED USAGE, REDUCING THE POTENTIAL FOR CRASHES OR LOSS OF CONTROL INCIDENTS TO BE CAUSED BY THE ALLEGED DEFECT. FORD IMPLEMENTED A 'SHOT PEENING' PROCESS IN JUNE 2006 WHICH REDUCED THE WHEEL'S SURFACE STRESS AND SIGNIFICANTLY IMPROVED ITS DURABILITY, AND ODI IS UNAWARE OF ANY FAILURES OF SHOT PEENED WHEELS (SERVICE PART NUMBER 7L1Z-1015-B).FORD'S TESTING SHOWED A SLIGHTLY REDUCED DURABILITY FOR THE NON-SHOT PEENED WHEELS WHEN 'LT' INSTEAD OF FORD APPROVED 'P' METRIC TYPE TIRES ARE USED. A SAFETY-RELATED DEFECT HAS NOT BEEN IDENTIFIED AT THIS TIME AND FURTHER USE OF AGENCY RESOURCES DOES NOT APPEAR TO BE WARRANTED.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST.THE AGENCY WILL TAKE FURTHER ACTION IF WARRANTED BY FURTHER C
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