IllustrationI WAS DRIVING AROUND 46MPH, AND IN THE MIDDLE OF DRIVING, MY TRUCK CUT OFF FOR AROUND 5 SECONDS. I ALMOST GOT BY THE TRUCK BEHIND ME. MY TRUCK KICKED BACK ON BY ITSELF, ALL WHY I WAS DRIVING. I WAS SO TERRIFIED THE TRUCK BEHIND ALMOST REAR ENDED ME. *TR
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
Vehicle Speed Control complaints
29 reportsTL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING 65 MPH, THE FAIL SAFE MODE WARNING LIGHT ILLUMINATED AS THE VEHICLE INDEPENDENTLY DECELERATED AND STALLED. THE VEHICLE WAS TOWED TO THE DEALER, WHO STATED THAT THE THROTTLE BODY WOULD NEED CLEANING. THE VEHICLE WAS REPAIRED BUT THE FAILURE RECURRE…
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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING 65 MPH, THE FAIL SAFE MODE WARNING LIGHT ILLUMINATED AS THE VEHICLE INDEPENDENTLY DECELERATED AND STALLED. THE VEHICLE WAS TOWED TO THE DEALER, WHO STATED THAT THE THROTTLE BODY WOULD NEED CLEANING. THE VEHICLE WAS REPAIRED BUT THE FAILURE RECURRED SEVERAL MONTHS LATER. THE VEHICLE WAS TAKEN BACK TO THE DEALER, WHO STATED THAT THE ENTIRE THROTTLE BODY WOULD NEED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURE WAS CONTACTED. THE APPROXIMATE FAILURE MILEAGE WAS 96,000.
VEHICLE SIMPLY SHUTS OFF AT ANY TIME AND SHOWS 'ENGINE FAIL SAFE MODE'. THIS HAS HAPPENED APPROXIMATELY 15 TIMES SINCE WE BOUGHT THE VEHICLE (USED) IN MARCH 2012 (MOST RECENTLY ON 10/13). I HAVE RESEARCHED THIS ONLINE AND MANY OTHER OWNERS HAVE THE SAME COMPLAINT. WE REPLACED THE TPS AT A COST OF AROUND $300 AS A POSSIBLE FIX AN…
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VEHICLE SIMPLY SHUTS OFF AT ANY TIME AND SHOWS 'ENGINE FAIL SAFE MODE'. THIS HAS HAPPENED APPROXIMATELY 15 TIMES SINCE WE BOUGHT THE VEHICLE (USED) IN MARCH 2012 (MOST RECENTLY ON 10/13). I HAVE RESEARCHED THIS ONLINE AND MANY OTHER OWNERS HAVE THE SAME COMPLAINT. WE REPLACED THE TPS AT A COST OF AROUND $300 AS A POSSIBLE FIX AND THIS WORKED FOR ABOUT 6 MONTHS - NOW THE PROBLEM IS BACK AND MY RESEARCH INDICATES WE NEED TO HAVE THE THROTTLE BODY REPLACED. THIS WILL COST US AROUND $500 - FOR A TOTAL REPAIR COST OF AROUND $800 - WHICH WE CANNOT AFFORD! FORD HAS LITERALLY $HUNDREDS OF MILLIONS TO TAKE CARE OF THIS AND MUST RECALL DUE TO THIS ISSUE - THERE IS NO EXCUSE TO ALLOW THIS DANGEROUS PROBLEM TO CONTINUE. FORD MOTOR CO. OWES ME $800 DUE TO THEIR POOR ENGINEERING AND UNWILLINGNESS TO SOLVE THIS ISSUE - THEY ARE GREEDY CROOKS. *TR
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 20 MPH, THE ENGINE STALLED AND THE WARNING INDICATOR ILLUMINATED. THE VEHICLE WAS RESTARTED AND RESUMED NORMALLY. THE FAILURE OCCURRED FOUR TIMES. THE VEHICLE WAS TAKEN TO A DEALER FOR DIAGNOSIS. THE TROUBLE CODES DETECTED A FAULTY …
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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 20 MPH, THE ENGINE STALLED AND THE WARNING INDICATOR ILLUMINATED. THE VEHICLE WAS RESTARTED AND RESUMED NORMALLY. THE FAILURE OCCURRED FOUR TIMES. THE VEHICLE WAS TAKEN TO A DEALER FOR DIAGNOSIS. THE TROUBLE CODES DETECTED A FAULTY THROTTLE BODY. THE VEHICLE HAD NOT BEE REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE PROBLEM. THE APPROXIMATE FAILURE MILEAGE WAS 62,000.
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED WHILE DRIVING AND DEPRESSING THE BRAKES IN ORDER TO STOP THE VEHICLE, IT ACCELERATED. RECENTLY, THE CONTACT BEGAN TO DRIVE IN REVERSE OUT OF A PARKING SPACE AND THE VEHICLE ACCELERATED AND CRASHED INTO ANOTHER VEHICLE. THE POLICE WERE NOTIFIED BUT A REPORT WAS NOT F…
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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED WHILE DRIVING AND DEPRESSING THE BRAKES IN ORDER TO STOP THE VEHICLE, IT ACCELERATED. RECENTLY, THE CONTACT BEGAN TO DRIVE IN REVERSE OUT OF A PARKING SPACE AND THE VEHICLE ACCELERATED AND CRASHED INTO ANOTHER VEHICLE. THE POLICE WERE NOTIFIED BUT A REPORT WAS NOT FILED. THERE WERE NO INJURIES ASSOCIATED WITH THE CRASH. THE VEHICLE WAS NOT INSPECTED BY A DEALER NOR AN INDEPENDENT MECHANIC. THE MANUFACTURER WAS CONTACTED AND THEY OFFERED NO ASSISTANCE. THE FAILURE MILEAGE WAS APPROXIMATELY 49,000. THE CURRENT MILEAGE WAS APPROXIMATELY 69,000. *TR
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT WHILE ATTEMPTING TO STOP AT A TRAFFIC STOP, THE VEHICLE STALLED WITHOUT WARNING. THE VEHICLE WAS TAKEN TO THE DEALER. THE TECHNICIAN DIAGNOSED THAT THE THROTTLE BODY WAS DEFECTIVE AND NEEDED TO BE REPLACED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE BUT DID…
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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT WHILE ATTEMPTING TO STOP AT A TRAFFIC STOP, THE VEHICLE STALLED WITHOUT WARNING. THE VEHICLE WAS TAKEN TO THE DEALER. THE TECHNICIAN DIAGNOSED THAT THE THROTTLE BODY WAS DEFECTIVE AND NEEDED TO BE REPLACED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE BUT DID NOT OFFER ANY ASSISTANCE SINCE THE VEHICLE WAS NOT INCLUDED IN ANY RECALLS. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 85,000 AND THE CURRENT MILEAGE WAS 94,000.
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT WAS TRAVELING 55 MPH WHEN THE ENGINE FAIL SAFE MODE WARNING LIGHT ILLUMINATED, CAUSING THE VEHICLE TO LOOSE POWER. THE VEHICLE WAS TAKEN TO THE DEALER AND THE CONTACT WAS TOLD THAT THE THROTTLE BODY NEEDED TO BE REPLACED. THE VIN WAS NOT AVAILABLE. THE FAILURE AND THE CURR…
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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT WAS TRAVELING 55 MPH WHEN THE ENGINE FAIL SAFE MODE WARNING LIGHT ILLUMINATED, CAUSING THE VEHICLE TO LOOSE POWER. THE VEHICLE WAS TAKEN TO THE DEALER AND THE CONTACT WAS TOLD THAT THE THROTTLE BODY NEEDED TO BE REPLACED. THE VIN WAS NOT AVAILABLE. THE FAILURE AND THE CURRENT MILEAGES WERE 113,000.
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT THE VEHICLE DECELERATED AND ENTERED INTO FAIL SAFE MODE WHILE DRIVING 55 MPH. THE VEHICLE WOULD NOT ACCELERATE FURTHER ONCE IT ENTERED FAIL SAFE MODE. THE CONTACT SHUT THE VEHICLE OFF AND UPON RESTART, THE VEHICLE OPERATED AS NORMAL. THE FAILURE RECURRED ONCE. …
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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT THE VEHICLE DECELERATED AND ENTERED INTO FAIL SAFE MODE WHILE DRIVING 55 MPH. THE VEHICLE WOULD NOT ACCELERATE FURTHER ONCE IT ENTERED FAIL SAFE MODE. THE CONTACT SHUT THE VEHICLE OFF AND UPON RESTART, THE VEHICLE OPERATED AS NORMAL. THE FAILURE RECURRED ONCE. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER AND THE CONTACT WAS INFORMED THAT THE THROTTLE BODY NEEDED TO BE REPLACED. THE VEHICLE WAS IN THE PROCESS OF BEING REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE, BUT OFFERED NO ASSISTANCE. THE FAILURE MILEAGE WAS 103,000. UPDATED 8/23/12 *CN UPDATED 09/06/2012 *JS
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT THE VEHICLE STALLED NUMEROUS TIMES WITH THE ILLUMINATION OF THE CHECK ENGINE LIGHT AFTER THE FAILURE OCCURRED. THE VEHICLE WAS TAKEN TO THE DEALER AND A DIAGNOSTIC WAS PERFORMED, WHICH LOCATED THE FAILURE AT THE THROTTLE BODY. THE VEHICLE WAS NOT REPAIRED. THE …
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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT THE VEHICLE STALLED NUMEROUS TIMES WITH THE ILLUMINATION OF THE CHECK ENGINE LIGHT AFTER THE FAILURE OCCURRED. THE VEHICLE WAS TAKEN TO THE DEALER AND A DIAGNOSTIC WAS PERFORMED, WHICH LOCATED THE FAILURE AT THE THROTTLE BODY. THE VEHICLE WAS NOT REPAIRED. THE FAILURE AND THE CURRENT MILEAGE WAS 88,000.
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING 15 MPH ON THE HIGHWAY, THE VEHICLE UNEXPECTEDLY STALLED. AN ENGINE FAIL SAFE LIGHT ALSO BEGAN TO ILLUMINATE ON THE INSTRUMENT PANEL. BOTH THE DEALER AND MANUFACTURER WERE NOTIFIED, BUT DENIED ANY ASSISTANCE WITH REPAIRS OF THE FAILURE. THE VEHICLE…
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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING 15 MPH ON THE HIGHWAY, THE VEHICLE UNEXPECTEDLY STALLED. AN ENGINE FAIL SAFE LIGHT ALSO BEGAN TO ILLUMINATE ON THE INSTRUMENT PANEL. BOTH THE DEALER AND MANUFACTURER WERE NOTIFIED, BUT DENIED ANY ASSISTANCE WITH REPAIRS OF THE FAILURE. THE VEHICLE WAS ON 01/06/12 AT THE CONTACT'S EXPENSE. THE APPROXIMATE FAILURE AND CURRENT MILEAGES WERE 86,280. THE THROTTLE BODY AND MOTOR ASSEMBLY WERE REPLACED. UPDATED 06/27/12*JB
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