IllustrationWHEN THE TEMPERATURE IS BELOW FREEZING OUTSIDE THE DRIVER SIDE DOOR WILL NOT LOCK OR UNLOCK. THE DOOR OPENS WHILE DRIVING. THIS HAS BEEN HAPPENING SINCE THE VEHICLE AS NEWER (AND UNDER WARRANTY) DEALERS AND FACTORY ARE UNWILLING TO REPAIR THIS AS A GOOD WILL.
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 →How this year compares
Owner complaints by model year
Compare all Expedition years →Counts vary with age, sales and reporting. They are not failure rates.
What owners reported most
All reported categories
Tap a category to read its complaints. One report may name several components.
When problems were reported
Mileage at the reported incident
220–25K
3425–50K
5750–75K
6875–100K
63100–150K
19150K+
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
Structure complaints
19 reportsCORROSION PROBLEMS IN MANY DIFFERENT PARTS OF THE VEHICLE.
PAINT BUBBLING/BLISTERING UP ON BACK LIFT GATE.
THE PAINT ON THE LIFT GATE IS BUBBLING AND PEELING, CAUSED BY A PROBLEM WITH THE ALUMINUM. A PROBLEM THAT FORD WAS AWARE OF BEFORE MY CAR WAS SOLD.
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
RUST IN THE CHANNELS OF THE ROOF HAS PENETRATED COMPLETELY THROUGH THE SHEET METAL. VEHICLE HAS BEEN WELL MAINTAINED AND IS OTHERWISE IN PERFECT CONDITION. *TR
I WAS DRIVING ON A TWO LANE HIGHWAY, FM 185. I WAS DRIVING NORTHEAST WHILE THE OTHER DRIVER WAS SOMEWHAT STOPPED HEADING WEST, TRYING TO TURN SOUTH ONTO CATTLE DRIVE. THE OTHER DRIVER WAS STOPPED AT AN INTERSECTION AWAITING TO TURN LEFT. THE OTHER DRIVER TURNED LEFT IN FRONT OF ME AS I WAS HEADED STRAIGHT. THE INITIAL IMPAC…
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I WAS DRIVING ON A TWO LANE HIGHWAY, FM 185. I WAS DRIVING NORTHEAST WHILE THE OTHER DRIVER WAS SOMEWHAT STOPPED HEADING WEST, TRYING TO TURN SOUTH ONTO CATTLE DRIVE. THE OTHER DRIVER WAS STOPPED AT AN INTERSECTION AWAITING TO TURN LEFT. THE OTHER DRIVER TURNED LEFT IN FRONT OF ME AS I WAS HEADED STRAIGHT. THE INITIAL IMPACT WAS DRIVER'S FRONT SIDE AND THEN DOWN THE DRIVERS SIDE DOOR. WE HIT, AND THEN MY VEHICLE DID A 180 DEGREE TURN WHICH TURNED MY VEHICLE AROUND FACING MY INITIAL PATH OF DIRECTION. MY AIRBAGS DID NOT DEPLOY. I HAD CURTAIN SIDE AIRBAGS, DRIVER, AND PASSENGER AIR BAGS AS WELL. THE AIRBAGS OF THE CAR CAUSING THE ACCIDENT DID DEPLOY. *TR
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
I HAVE A 2006 FORD EXPEDITION EDDIE BAUER UNDER 5 YEARS OLD THAT THE TAILGATE IS SEVERELY BLISTERED ALL OVER, PAINT HAS EVEN POPPED OFF OF IT. THERE IS ALSO SOME ON THE HOOD. THE LOCAL FORD DEALERSHIP ADMITTED THAT FORD HAD A PROBLEM WITH THE BLISTERING PAINT AND TOLD ME HOW BAD MY VEHICLE WAS. THEY TOOK PICTURES AND SENT TO FOR…
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I HAVE A 2006 FORD EXPEDITION EDDIE BAUER UNDER 5 YEARS OLD THAT THE TAILGATE IS SEVERELY BLISTERED ALL OVER, PAINT HAS EVEN POPPED OFF OF IT. THERE IS ALSO SOME ON THE HOOD. THE LOCAL FORD DEALERSHIP ADMITTED THAT FORD HAD A PROBLEM WITH THE BLISTERING PAINT AND TOLD ME HOW BAD MY VEHICLE WAS. THEY TOOK PICTURES AND SENT TO FORD. FORD REP DENIED IT AND I WAS TOLD THAT EVEN IF HOLES APPEARED AS A RESULT NOW THEY WOULD DO NOTHING FOR ME BECAUSE THEY HAD ALREADY DENIED AND ONLY LOOK AT A CLAIM FOR ONE THING ONE TIME. I PURSUED FURTHER BY CALLING CUSTOMER SERVICE AND EMAILING THEM AS WELL. THE CUSTOMER SERVICE REP ALSO ADMITTED THERE WAS A PROBLEM WITH PAINT BLISTER BUT COULD DO NOTHING FOR ME BECAUSE IT HAD ALREADY BEEN DENIED. I HAVE OWNED FORDS ALL OF MY LIFE AND EVEN WORKED FOR A LINCOLN MERCURY DEALERSHIP FOR SEVERAL YEARS. I AM CONTINUING TO PURSUE THIS AS FAR AS I CAN AND ASK FOR ANY HELP THAT CAN BE OFFERED IN THIS MATTER. *TR
REAR DOOR PAINT BLISTERS. *TR
Official recalls
205V520000 · 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
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