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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

Power Train complaints

22 reports
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78,468 miles · Apr 12, 2013
Power Train

DRIVING 30MPH IN (D) WITH O/D ON AND LOST FORWARD MOMENTUM JUST LIKE I PUT IT IN NEUTRAL. HAD TO DRIVE IN L2 TO GET HOME.THIS WAS THE FIRST AND ONLY TIME THIS HAPPENED. TOOK A TEST DRIVE AFTER I CHECKED FLUID LEVELS THAT WERE FULL AND PROPER WHICH I WISHED WERE LOW(EASY FIX).I TOOK IT DOWN THE ROAD IN D BUT SLIPPED OUT ABOUT 50'…

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DRIVING 30MPH IN (D) WITH O/D ON AND LOST FORWARD MOMENTUM JUST LIKE I PUT IT IN NEUTRAL. HAD TO DRIVE IN L2 TO GET HOME.THIS WAS THE FIRST AND ONLY TIME THIS HAPPENED. TOOK A TEST DRIVE AFTER I CHECKED FLUID LEVELS THAT WERE FULL AND PROPER WHICH I WISHED WERE LOW(EASY FIX).I TOOK IT DOWN THE ROAD IN D BUT SLIPPED OUT ABOUT 50' LATER BUT I TOOK IT OUT OF O/D OVERDRIVE AND WENT DOWN THE ROAD FINE FOR 2 MILES BUT DIDN'T WANT TO DRIVE IT ANYMORE UNTIL I TOOK IT TO THE TRANSMISSION GARAGE. WE TREAT OUR VEHICLES EXCELLENT AND I HAVE NEVER HAULED ANYTHING BUT FAMILY AROUND,NO TRAILERS,NO PLOWS..NO PULLING OF ANY KIND.THERE WERE NO PRIOR INDICATORS EXCEPT A SMALL WHINE THAT GOT A LITTLE LOUDER WHEN I ACCELERATED BUT ONLY HEARD IT MAYBE 10 TIMES AT MOST BUT DON'T KNOW IF THAT MEANS ANYTHING WITH THE TRANSMISSION...PLEASE HELP WERE NOT RICH$$ *TR

NHTSA ODI #10506064

130,000 miles · Mar 6, 2013
Power Train

TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING 40 MPH, THE TRANSMISSION SLIPPED. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC FOR INSPECTION AND THEY STATED THAT THE TRANSMISSION NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED. THE FAILURE MILEAGE WAS 130…

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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING 40 MPH, THE TRANSMISSION SLIPPED. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC FOR INSPECTION AND THEY STATED THAT THE TRANSMISSION NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED. THE FAILURE MILEAGE WAS 130,000. *TR

NHTSA ODI #10501850

88,000 miles · Jul 18, 2012
EnginePower Train

ENGINE WAS LOSING POWER UNDER LOAD (ONLY WHILE ACCELERATING). NO CHECK ENGINE LIGHT EVER CAME ON. AT 88,000 MILES FIGURED THAT NOT ONLY WILL I REPLACE ALL 8 SPARK PLUGS, BUT WOULD REPLACE ALL 8 COIL PACKS AS WELL. UPON REMOVAL ON THE SPARK PLUGS, 1 SPARK PLUG BROKE (SO FAR) LEAVING THE BOTTOM PIECE INSIDE THE HEAD. FORD KNOWS AB…

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ENGINE WAS LOSING POWER UNDER LOAD (ONLY WHILE ACCELERATING). NO CHECK ENGINE LIGHT EVER CAME ON. AT 88,000 MILES FIGURED THAT NOT ONLY WILL I REPLACE ALL 8 SPARK PLUGS, BUT WOULD REPLACE ALL 8 COIL PACKS AS WELL. UPON REMOVAL ON THE SPARK PLUGS, 1 SPARK PLUG BROKE (SO FAR) LEAVING THE BOTTOM PIECE INSIDE THE HEAD. FORD KNOWS ABOUT THIS PROBLEM, AS IT CAN LEAD MANY LIKE MYSELF WITH AN OUTRAGEOUS EXPENSE TO PROPERLY REMOVE THE BROKEN SPARK PLUG AND CAN IN THE LONG RUN DAMAGE THE ALUMINUM HEAD TOO. THEY ARE MOTOR CRAFT PLATINUM (CERAMIC INSIDE) SPARK PLUGS. NAPA SELLS A TOOL TO EXTRACT THE BROKE PLUG OUT. WHY IN THE WORLD THIS IS ALLOWED TO CONTINUE ON WITHOUT A RECALL IS BEYOND ME. FORD KNOWS ABOUT THESE ISSUES AND SHOULD HAVE A MASSIVE RECALL FOR THE ANY VEHICLE THAT CONTAINS THESE SPARK PLUGS, LIKE MY 2006 MODEL WITH A 5.3L DOES. I HAVE CALLED FORD AND FILED A FORMER COMPLAINT AND MANY OTHERS NEED TO DO SO AS WELL. I AM ALSO GOING TO FILE A COMPLAINT WITH THE BBB, AS I SPENT A HUGE CHUNK OF CHANGE AND PROPERLY MAINTAIN MY VEHICLE ON A DAILY BASIS. IF MY TRUCK HAS TO GO INTO A REPAIR SHOP TO HAVE THIS PLUG REMOVED, I WILL BE VERY DISAPPOINTED IN FORD'S CUSTOMER SERVICE. I HAVE 4 FORDS TODAY.......NOTHING HAS EVER BEEN THIS COSTLY! I HAVE A 71 BRONCO, 98 EXPLORER, 01 RANGER, AND 06 EXPEDITION. I GUESS THIS WILL DETERMINE IF I WILL STAY AS A FORD OWNER IN THE FUTURE. *TR

NHTSA ODI #10466460

10,756 miles · Apr 20, 2012
Latches/locks/linkagesPower TrainService Brakes, Hydraulic

2006 FORD EXPEDITION LIMITED. CONSUMER WRITES IN REGARDS WARRANTY REPAIR DISPUTE AND DRIVER'S SIDE POWER WINDOW BEING EXTREMELY SLOW IN THE CLOSING OPERATION *TGW THE DEALER LUBED THE WINDOW AND STATED THERE WAS NO PROBLEM FOUND. AFTER COMPLAINING SEVERAL TIMES ABOUT THE WINDOW, THE DEALER FINALLY DETERMINED THERE WAS A PROBLEM…

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2006 FORD EXPEDITION LIMITED. CONSUMER WRITES IN REGARDS WARRANTY REPAIR DISPUTE AND DRIVER'S SIDE POWER WINDOW BEING EXTREMELY SLOW IN THE CLOSING OPERATION *TGW THE DEALER LUBED THE WINDOW AND STATED THERE WAS NO PROBLEM FOUND. AFTER COMPLAINING SEVERAL TIMES ABOUT THE WINDOW, THE DEALER FINALLY DETERMINED THERE WAS A PROBLEM. HOWEVER, THE CONSUMER WAS INFORMED THE PARTS AND LABOR WERE NOT COVERED UNDER THE EXTENDED WARRANTY. THE CONSUMER STATED THE PROBLEM EXISTED GOING BACK TO DEC 11, 2006 AND THE DEFECT WAS NOT ADDRESSED OR CORRECTED WHILE THE VEHICLE WAS UNDER THE ORIGINAL FACTORY WARRANTY. THE CONSUMER STATED HE SHOULD NOT BE RESPONSIBLE FOR REPAIRS THAT WERE CALLOUSLY OVERLOOKED AND IGNORED BY THE DEALER. ALSO, THE LOWER RADIATOR SUPPORT TO THE BODY MOUNT WAS SEVERELY RUSTED AND SHOWED SIGNS OF ACTUAL MATERIAL FAILURE. THE CONSUMER STATED THE CONDITION CAN AND WILL EVOLVE INTO THE ROOT CAUSE OF BOTH MECHANICAL AND SAFETY RELATED FAILURES. THE MAJOR BODY AND FRONT FRAME SUPPORT FAILING UNDER DRIVING CONDITIONS COULD LEAD TO ENGINE FAILURE, AND LOSS OF CONTROL OF THE VEHICLE. THE MOST SERIOUS SAFETY CONCERN, WAS THE FRONT BRAKE LINES WHICH WERE SHOWING SIGNS OF SERIOUS RUST. THE DEALER INFORMED THE CONSUMER THE LINES COULD ONLY BE REPLACED UNDER WARRANTY IF THERE WERE SIGNS OF LEAKAGE. THE CONSUMER STATED CORROSION IN THE FORM OF RUST WOULD COMPROMISE THE INTEGRITY OF THE STEEL BRAKE LINES, ALLOWING BRAKE FLUID TO LEAK OUT RESULTING IN A TOTAL LOSS OF BRAKING POWER. THE LEFT REAR DOOR WOULD NOT OPEN FROM THE INSIDE, THE DRIVER'S FRONT DOOR HAD TO BE SLAMMED IN ORDER FOR IT TO CLOSE PROPERLY, THE FRONT AXLE DRIVE PINION WAS LEAKING AND HAD TO BE REPLACED.*JB

NHTSA ODI #10456236

114,000 miles · Sep 9, 2011
Power Train

TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT WAS DRIVING 55 MPH WHEN THE VEHICLE STALLED. THE ENGINE SAFE MODE LIGHT ILLUMINATED AFTER THE FAILURE AND THE VEHICLE WAS TOWED TO THE DEALER. THE MANUFACTURER WAS CONTACTED TO REPORT THE FAILURE. THE VEHICLE WAS NOT REPAIRED AND THE VIN WAS UNAVAILABLE. THE FAILURE MILEAG…

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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT WAS DRIVING 55 MPH WHEN THE VEHICLE STALLED. THE ENGINE SAFE MODE LIGHT ILLUMINATED AFTER THE FAILURE AND THE VEHICLE WAS TOWED TO THE DEALER. THE MANUFACTURER WAS CONTACTED TO REPORT THE FAILURE. THE VEHICLE WAS NOT REPAIRED AND THE VIN WAS UNAVAILABLE. THE FAILURE MILEAGE WAS 114,000 AND THE CURRENT MILEAGE WAS 116,000.

NHTSA ODI #10424423

76,000 miles · Apr 4, 2011
Engine And Engine CoolingPower Train

VEHICLE HAS BEEN SPUTTERING WHEN ACCELERATING AT ABOUT 40MPH. SPARK PLUGS ARE "SEERED" AND FORD MECHANIC TELLS US ITS A KNOWN PROBLEM, BUT NOT COVERED UNDER THE WARRANTY BECAUSE SPARK PLUGS ARE CONSIDERED MAINTENANCE. THE MANUAL SAYS WE THE SCHEDULED MAINTENANCE IS 100,000 MILES AND WE ARE ONLY AT 76,000. IF THEY ARE KNOWN TO B…

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VEHICLE HAS BEEN SPUTTERING WHEN ACCELERATING AT ABOUT 40MPH. SPARK PLUGS ARE "SEERED" AND FORD MECHANIC TELLS US ITS A KNOWN PROBLEM, BUT NOT COVERED UNDER THE WARRANTY BECAUSE SPARK PLUGS ARE CONSIDERED MAINTENANCE. THE MANUAL SAYS WE THE SCHEDULED MAINTENANCE IS 100,000 MILES AND WE ARE ONLY AT 76,000. IF THEY ARE KNOWN TO BE FAULTY AND WE ARE NOT NEAR THE SCHEDULED/RECOMMENDED MAINTEANCE THEN SHOULDN'T THIS BE A WARRANTY ISSUE? I THINK FORD IS MILKING ITS CUSTOMERS WITH FAULTY PARTS AS I HAD THE SAME ISSUE WITH MY BRAKES. IT FEELS AS IF I AM LANDING A PLANE WHEN I COME TO A STOP WITH ALL THE SHAKNIG AN RATTLING. I WAS TOLD THIS IS A KNOWN ISSUE WITH THE FORD BRAKES - THEY JUST WARP. *TR

NHTSA ODI #10394140

59,600 miles · Aug 8, 2009
Power Train

MY CAR STALLED AT AN INTERSECTION LIGHT. IT WAS DRIVING POORLY-MAKING LOUD NOISES AND STICKING AS I PRESSED THE GAS PEDAL AS IF THE TRANSMISSION WAS GOING OUT. WE WERE TOLD IT WAS COVERED UNDER THE POWERTRAIN WARRANTY AND WE TOOK IT IN TO FORD. THEY TOLD US IT WAS THE TIMING CHAIN BUT BECAUSE THERE WAS EVIDENCE OF SLUDGE, THE WA…

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MY CAR STALLED AT AN INTERSECTION LIGHT. IT WAS DRIVING POORLY-MAKING LOUD NOISES AND STICKING AS I PRESSED THE GAS PEDAL AS IF THE TRANSMISSION WAS GOING OUT. WE WERE TOLD IT WAS COVERED UNDER THE POWERTRAIN WARRANTY AND WE TOOK IT IN TO FORD. THEY TOLD US IT WAS THE TIMING CHAIN BUT BECAUSE THERE WAS EVIDENCE OF SLUDGE, THE WARRANTY CLAIM WAS DENIED BY FORD. THEY CLAIM WE DID NOT MAINTAIN OUR VEHICLE. WE BELIEVE IT IS A DEFECT IN THE SYSTEM. WE HAVE MAINTAINED THE OIL ON A REGULAR BASIS AND HAVE HAD OTHER MAJOR REPAIRS WITH THIS CAR. IT HAS HAD A NEW TRANSMISSION AT 35,000 AS WELL AS A NEW SUSPENSION SYSTEM AND ELECTRICAL FAILURE WITH THE STEREO/DVD SYSTEM. THERE HAS NEVER BEEN ANY PRIOR EVIDENCE OF SLUDGE. AN ACCIDENT COULD HAVE OCCURRED WHEN THE CAR STALLED. *TR

NHTSA ODI #10279744

15,000 miles · Dec 6, 2007
Electronic Stability Control (esc)Power TrainService Brakes, Hydraulic

NO INCIDENT YET. VEHICLES TRACTION CONTROL FAILS, ABS FAILS AND 4 WHEEL DRIVE FAILS ALL AT THE SAME TIME. *TR

NHTSA ODI #10211048

18,500 miles · Jul 9, 2007
Power TrainCrash

THE DEALERSHIP HAD JUST FINISHED REMOVING AN EXTRA ALARM THEY HAD INSTALLED ON THE 2006 FORD EXPEDITION. I WAS SITTING IN THE FRONT SEAT AND WAS EXCITED ABOUT GETTING A NEW TRUCK, AND ENDED UP SHIFTING IT OUT OF GEAR WITHOUT MY FOOT BEING ON THE BRAKE. I TOLD OUR SALES PERSON AND THEY WANTED TO FIX IT BEFORE WE TOOK DELIVERY OF…

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THE DEALERSHIP HAD JUST FINISHED REMOVING AN EXTRA ALARM THEY HAD INSTALLED ON THE 2006 FORD EXPEDITION. I WAS SITTING IN THE FRONT SEAT AND WAS EXCITED ABOUT GETTING A NEW TRUCK, AND ENDED UP SHIFTING IT OUT OF GEAR WITHOUT MY FOOT BEING ON THE BRAKE. I TOLD OUR SALES PERSON AND THEY WANTED TO FIX IT BEFORE WE TOOK DELIVERY OF THE TRUCK. THE NEXT DAY THEY CALLED AND TOLD US IT WAS READY. THEY HAD REPLACED THE SHIFT ACTUATOR. WE CHECKED IT AND IT SEEMED TO WORK FINE. A YEAR LATER, MY KIDS WERE GETTING IN THE CAR, I WENT BACK INTO THE HOUSE TO GET SOMETHING I FORGOT, AND MY 2 YEAR OLD CLIMBED IN O THE FRONT SEAT AND WAS PLAYING AND PULLED THE TRUCK OUT OF GEAR WITHOUT HER FOOT BEING ON THE BRAKE AND NO KEYS IN THE IGNITION. THE TRUCK ROLLED OUT OF DRIVEWAY ACROSS THE STREET AND DOWN MY NEIGHBOR'S YARD AND HIT A TREE. LUCKILY NO ONE WAS HURT. MY 10 YEAR OLD WAS IN THE BACK SEAT AND MY 7 YEAR OLD WAS STANDING NEXT TO THE TRUCK. THE DEALERSHIP SAID THEY WOULD FIX THE PROBLEM BECAUSE IT? WAS STILL UNDER WARRANTY. NEITHER FORD NOR DEALERSHIP FELT THAT THEY SHOULD PAY FOR THE $1,343.18 WORTH OF DAMAGES TO OUR VEHICLE.*AK

NHTSA ODI #10195689

11,000 miles · Mar 11, 2007
Power Train

AT ABOUT 11,000 MILES I HAD THE FIRST INCIDENT WHILE IN NORMAL TRAFFIC GOING ABOUT 45 MPH. FELT LIKE THE TRANSMISSION SLIPPED. NO POWER DURING 1ST AND 2ND GEAR CHANGE. A FEW DAYS LATER THE SAME THING HAPPEN WHILE ENTERING THE INTERSTATE. WHILE TRYING TO ACCELERATE THERE WAS NO POWER, NEARLY HIT BY SEMI-TRUCK, COULDN'T GET OV…

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AT ABOUT 11,000 MILES I HAD THE FIRST INCIDENT WHILE IN NORMAL TRAFFIC GOING ABOUT 45 MPH. FELT LIKE THE TRANSMISSION SLIPPED. NO POWER DURING 1ST AND 2ND GEAR CHANGE. A FEW DAYS LATER THE SAME THING HAPPEN WHILE ENTERING THE INTERSTATE. WHILE TRYING TO ACCELERATE THERE WAS NO POWER, NEARLY HIT BY SEMI-TRUCK, COULDN'T GET OVER 60 MPH AND THE CHECK ENGINE LIGHT CAME ON. I SLOWED BACK ON THE ACCELERATOR AND LIGHT WENT OFF AND POWER SLOWLY CAME BACK. TOOK VEHICLE TO FORD AT 12,000+ MILES, KEPT IT FOR SEVERAL DAYS. SAID IT WAS A COMPUTER MODULE, CHANGED IT, PICKED VEHICLE UP AND NOT 2 MILES DOWN THE ROAD THE SAME THING HAPPENED AGAIN. DIDN'T HAVE THE TIME TO TAKE IT RIGHT BACK IN NOT TO MENTION THERE RENTAL CAR EXPERIENCE WAS EQUALLY HORRIBLE. IT'S IN THEIR SHOP NOW 3/10 AND I'M AT 22,000 MILES AND IT HAPPENS EVERY TIME I ACCELERATE. IT'S A VERY DANGEROUS PROBLEM. NOW THEY SAY THEY THINK IT'S SOMETHING TO DO WITH THE TORQUE CONVERTER AND HAVE ORDERED PARTS. I'M ALSO HAVING A PROBLEM WITH IT NOT STARTING AFTER DRIVING, GETTING OUT AND GETTING BACK IN WITHIN ABOUT 30 MINUTES. WE'LL SEE NEXT WEEK WHAT THE OUTCOME IS! *JB

NHTSA ODI #10184734

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