IllustrationTHE VEHICLE EXPLODED IN OUR DRIVEWAY. IT HAD NOT BEEN DRIVEN OR TURNED ON IN ALMOST 2 WEEKS. IT WAS LOCKED. THIS CAUGHT ONE OTHER CAR ON FIRE AND TO EXPLODED AND ANOTHER TO GET BODY MELT DOWN ON ONE SIDE.
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
Unknown Or Other complaints
14 reportsMY 2006 FORD EXPEDITION SHUT OFF WITHOUT ANY WARNINGS IN THE MIDST OF ME DRIVING THE TRUCK EVERYTHING SHUTS DOWN IT'S HARD FOR ME TO STEER MY VEHICLE AND THE BRAKES LOCKS UP THIS WAS SO SCARY DRIVING THE EXPRESSWAY AND TRYING TO MANEUVER A STALLED VEHICLE
THE TRANSMISSIONS OVERDRIVE (84,000 ) STOP WORKING EFFICIENTLY WITHOUT ANY SIGNAL OF PROBLEM. WHEN IN MOTION REACHING 35 MILES/HOUR THE TRANSMISSION STOPS.
AT APPROXIMATELY 45 MILES AN HOUR THERE IS A GRINDING NOISE THAT SOUNDS LIKE THE TRANSMISSION. IF I SPEED UP IT GOES AWAY. AFTER DRIVE FOR AWHILE THE OVERDIVE LIGHT STARTS TO BLINK. IF I TURN OFF THE ENGINE THE LIGHT STOPS BLINKING. THE CAR PERFORMS MUCH BETTER WITH THE OVERDIVE OFF. HAD THE TRANSMISSION REBUILT AND IT DIDN'T SO…
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AT APPROXIMATELY 45 MILES AN HOUR THERE IS A GRINDING NOISE THAT SOUNDS LIKE THE TRANSMISSION. IF I SPEED UP IT GOES AWAY. AFTER DRIVE FOR AWHILE THE OVERDIVE LIGHT STARTS TO BLINK. IF I TURN OFF THE ENGINE THE LIGHT STOPS BLINKING. THE CAR PERFORMS MUCH BETTER WITH THE OVERDIVE OFF. HAD THE TRANSMISSION REBUILT AND IT DIDN'T SOLVE THE PROBLEM. THE TRANSMISSION SHOP SAYS THE PROBLEM IS NOT IN THE TRANSMISSUON ITSELF. FORD DEALER RECOMMENDED CHANGING THE TROTTLE SENSON, $100 LATER THAT DIDN'T WORK. MECHANICS IN TOWN CAN'T FIGURE IT OUT. IT SOUNDS LIKE 2 GEARS TRYING TO ENGAGE, THUS THE GRINDING NOISE. WHEN I DRIVE WITH THE OVERDRIVE OFF IT HAPPENS AT A HIGHER SPEED. ALWAYS HAPPENS WHEN DRIVI G UP A LONG INCLINE. GOING CRAZY WITH THIS PROBLEM.
I HAVE A 2006 FORD EXPEDITION EDDIE BAUER 4X2 AND MY PROBLEM STARTED AFTER I PURCHASED THE VEHICLE IN 2010. IN 2011 I WAS IN TAMPA, FL AFTER GASSING UP I WENT TO PUT THE VEHICLE IN GEAR AND THE GEAR SHIFT LEVER BROKE OFF THE VEHICLE HAD TO BE TOWED TO SARASOTA FORD IN SARASOTA, FL WHERE I LIVE. THAT'S THE FIRST TIME NOW THE SECO…
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I HAVE A 2006 FORD EXPEDITION EDDIE BAUER 4X2 AND MY PROBLEM STARTED AFTER I PURCHASED THE VEHICLE IN 2010. IN 2011 I WAS IN TAMPA, FL AFTER GASSING UP I WENT TO PUT THE VEHICLE IN GEAR AND THE GEAR SHIFT LEVER BROKE OFF THE VEHICLE HAD TO BE TOWED TO SARASOTA FORD IN SARASOTA, FL WHERE I LIVE. THAT'S THE FIRST TIME NOW THE SECOND TIME I WAS LEAVING FOR WORK AT 4:30 AM IN NOVEMBER OR DECEMBER OF 2014 I WAS IN MY DRIVEWAY AND WENT TO PUT THE VEHICLE IN GEAR WHEN THE GEAR SHIFT LEVER BROKE OFF. THE THIRD EVENT HAPPENED ON FRIDAY JULY 8, 2016 AT 4: 28 AM IN MY DRIVEWAY I WAS LEAVING FOR WORK AS I WENT TO PUT THE VEHICLE IN GEAR THE GEAR SHIFT LEVER BROKE OFF. I HAVE HAD TO MISS TWO DAYS OF WORK BY USING PTO/PAID TIME OFF WHICH IS MY VACATION TIME DUE TO THE GEAR SHIFT LEVER CONTINUALLY BREAKING OFF. SARASOTA FORD TOLD ME THAT THE SHIFT LEVER HAS BEEN DISCONTINUED SO THEY HAD TO LOCATE A USED PART FOR THE LAST REPAIR. I HAVE FILED TWO COMPLAINTS WITH FORD MOTOR COMPANY TO WHICH THEY WILL NOT DISCLOSE ANY FINDINGS OR OTHER RELATED COMPLAINTS ONLY THAT THERE ARE NO RECALLS. I HAVE HAD SARASOTA FORD CHARGE ME FOR A NEW PART THEN TAKE SOME MONEY OFF AFTER I FOUND OUT IT WAS A USED PART TO WHICH THEY NEVER NOTIFIED OR ASKED ME IF IT WAS OK TO PUT USED PARTS ON MY VEHICLE. THE SALES MANAGER BILL GODFREY LIED TO ME WHEN I ASKED FOR COPIES OF MY PRIOR INVOICES IN REFERENCE TO THIS ONGOING ISSUE. HE STATED THAT THE RECORDS WERE NOT ON SITE WHEN IN FACT THEY WERE AS I BELIEVE ONE OF THE FILE CLERKS ACTUALLY TOLD US THESE RECORDS WHERE ON SITE IN A OFFICE AND SHE SUPPLIED US WITH THE DOCUMENTS.
HAVE HAD AN A/C PROBLEMS OF THE COMPRESSOR GOING OUT 2007, 2009, 2011, 2013 AND 2016. A/C MAKES A NOISE IN THE BACK END ON PASSENGER SIDE. THEN IT BLOWS WARM AIR. ONLY TWICE DID IT LEAK CONDENSATION ON THE FLOOR BOARDS. HAVE ONLY HAD 2 OF THE COMPRESSOR REPAIRS UNDER WARRANTY AND THE REST HAVE BEEN OUT OF POCKET AT $800-$1200…
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HAVE HAD AN A/C PROBLEMS OF THE COMPRESSOR GOING OUT 2007, 2009, 2011, 2013 AND 2016. A/C MAKES A NOISE IN THE BACK END ON PASSENGER SIDE. THEN IT BLOWS WARM AIR. ONLY TWICE DID IT LEAK CONDENSATION ON THE FLOOR BOARDS. HAVE ONLY HAD 2 OF THE COMPRESSOR REPAIRS UNDER WARRANTY AND THE REST HAVE BEEN OUT OF POCKET AT $800-$1200. I HAVE CALLED FORD CUSTOMER RELATIONS; NO HELP. NO RECALLS AND NO TSB'S. THE VEHICLE HAS BEEN REPAIRED BY A FORD DEALER SERVICE DEPT. FOR ALL A/C REPAIRS. WHAT IS THE PROBLEMS?
MY 2006 FORD EXPEDITION WAS PARKED IN MY DRIVEWAY AT 7:00 AM WHEN I HEARD A CRASH. I LOOKED OUT THE WINDOW TO SEE THE BACK LIFT GATE GLASS HAD EXPLODED, ALL ELSE IN MY NEIGHBORHOOD WAS QUIET AT THAT HOUR. AS FAR AS I CAN TELL NO IMPACT FROM AN EXTERNAL SOURCE, IT WAS BACKED IN CLOSE TO A BOAT. I HAD DRIVEN THE VEHICLE TWO DAY…
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MY 2006 FORD EXPEDITION WAS PARKED IN MY DRIVEWAY AT 7:00 AM WHEN I HEARD A CRASH. I LOOKED OUT THE WINDOW TO SEE THE BACK LIFT GATE GLASS HAD EXPLODED, ALL ELSE IN MY NEIGHBORHOOD WAS QUIET AT THAT HOUR. AS FAR AS I CAN TELL NO IMPACT FROM AN EXTERNAL SOURCE, IT WAS BACKED IN CLOSE TO A BOAT. I HAD DRIVEN THE VEHICLE TWO DAYS PRIOR AND HAD NOTICED NO PROBLEM WITH THE REAR WINDOW. WHEN I CLEANED UP THE MESS I FOUND A GOOD AMOUNT OF THE SMALL GLASS PIECES WERE INSIDE THE VEHICLE, THE REMAINDER WERE ON THE GROUND BEHIND THE VEHICLE WITHIN TEN FEET OR SO. THE LARGEST PIECES OF GLASS WERE SMALLER THAN MY PALM.
FALSE ACTIVATION OF "ENGINE FAILURE MODE" SYSTEM. ENGINE WENT TO IDLE SPEED, ALL GAUGES READ NORMALLY AND NO WARNING LIGHTS CAME ON. ENGINE TEMPERATURE WAS IN NORMAL RANGE. "ENGINE FAILURE MODE" MESSAGE WAS DISPLAYED ON MESSAGE PANEL. I WAS ABLE TO SAFELY COAST OFF THE ROAD AND STOP THE VEHICLE. I TURNED THE IGNITION OFF, AND OB…
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FALSE ACTIVATION OF "ENGINE FAILURE MODE" SYSTEM. ENGINE WENT TO IDLE SPEED, ALL GAUGES READ NORMALLY AND NO WARNING LIGHTS CAME ON. ENGINE TEMPERATURE WAS IN NORMAL RANGE. "ENGINE FAILURE MODE" MESSAGE WAS DISPLAYED ON MESSAGE PANEL. I WAS ABLE TO SAFELY COAST OFF THE ROAD AND STOP THE VEHICLE. I TURNED THE IGNITION OFF, AND OBSERVED THAT THE ENGINE COOLANT LEVEL IN THE COOLANT TANK WAS NORMAL. I THEN RESTARTED THE ENGINE, AND VEHICLE THEN OPERATED NORMALLY.
'06 EXPEDITION WENT INTO ENGINE FAIL SAFE MODE AS MY WIFE WAS ATTEMPTING TO MAKE A LEFT HAND TURN CROSSING 2 LANES OF TRAFFIC AT A BUSY INTERSECTION. AFTER COASTING INTO A PARKING LOT, SHE TURNED IT OFF AND TURNED IT BACK ON. IT STARTED RIGHT UP AND SHE WENT ON HER WAY. TOOK IT TO A MECHANIC WHO SAID HE COULD FIND NOTHING WRONG.…
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'06 EXPEDITION WENT INTO ENGINE FAIL SAFE MODE AS MY WIFE WAS ATTEMPTING TO MAKE A LEFT HAND TURN CROSSING 2 LANES OF TRAFFIC AT A BUSY INTERSECTION. AFTER COASTING INTO A PARKING LOT, SHE TURNED IT OFF AND TURNED IT BACK ON. IT STARTED RIGHT UP AND SHE WENT ON HER WAY. TOOK IT TO A MECHANIC WHO SAID HE COULD FIND NOTHING WRONG. UPON FURTHER INVESTIGATION, I HAVE FOUND 100'S OF '06 EXPEDITIONS WITH THE SAME PROBLEM AND IT SEEMS TO POINT TO THE THROTTLE BODY. A RECENT AC REPAIR TO THIS CAR WAS ALMOST $800.00 AND NOW I AM HEARING TO REPAIR THE THROTTLE BODY IS UPWARD TO $700-$800. $1500 OF REPAIRS ON A CAR WITH ONLY 45,000 MILES IS UNACCEPTABLE. THE THROTTLE BODY PROBLEM IS VERY DANGEROUS AND FORD SHOULD RECALL THESE CARS AND FIND OUT WHY THIS IS HAPPENING BEFORE SOMEONE GETS HURT OR EVEN WORSE, KILLED. *LN
2006 FORD EXPEDITION, "ENGINE FAIL SAFE MODE" CAR HAS SHUT OFF WHILE DRIVING 5 TIMES IN THE LAST 6 MONTHS. THE ONLY WAY TO GET THE CAR MOVING IS TO START IT AGAIN. EXTREMELY UNSAFE. THIS VEHICLE WAS COVERED UNDER AN EXTENDED WARRANTY AND HAS GONE IN FOR SERVICE TO CORRECT THE PROBLEM. FORD CANNOT IDENTIFY THE PROBLEM! COMES…
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2006 FORD EXPEDITION, "ENGINE FAIL SAFE MODE" CAR HAS SHUT OFF WHILE DRIVING 5 TIMES IN THE LAST 6 MONTHS. THE ONLY WAY TO GET THE CAR MOVING IS TO START IT AGAIN. EXTREMELY UNSAFE. THIS VEHICLE WAS COVERED UNDER AN EXTENDED WARRANTY AND HAS GONE IN FOR SERVICE TO CORRECT THE PROBLEM. FORD CANNOT IDENTIFY THE PROBLEM! COMES UP WITH "NO CODE". I'M NOW OFF WARRANTY AND STUCK WITH A VERY UNSAFE VEHICLE! FORD NEEDS TO ADDRESS THIS PROBLEM IMMEDIATELY! *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