NHTSA owner reports · September 18, 2026 snapshot.
Vehicle Speed Control complaints
29 reportsClear category filter15,000 miles · Dec 14, 2011
Vehicle Speed Control
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING 70 MPH THE VEHICLE WENT INTO ENGINE FAIL SAFE MODE AND STALLED WITH WARNING. THE VEHICLE WAS LEFT WITH BRAKES, BUT THE VEHICLE WOULD NO LONGER ACCELERATE AND LOSS POWER STEERING. THE VEHICLE WAS TAKEN TO THE DEALER AND IT WAS DETERMINED THAT THE T…
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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING 70 MPH THE VEHICLE WENT INTO ENGINE FAIL SAFE MODE AND STALLED WITH WARNING. THE VEHICLE WAS LEFT WITH BRAKES, BUT THE VEHICLE WOULD NO LONGER ACCELERATE AND LOSS POWER STEERING. THE VEHICLE WAS TAKEN TO THE DEALER AND IT WAS DETERMINED THAT THE THROTTLE ACTUATOR SENSOR FAILED ON THE VEHICLE. THE VIN WAS NOT AVAILABLE. THE FAILURE MILEAGE AND CURRENT MILEAGES WERE 150,000.RL
NHTSA ODI #10439941
80,000 miles · Nov 27, 2011
Electrical SystemEngine And Engine CoolingVehicle Speed Control
WHILE DRIVING MY 2006 FORD EXPEDITION EDDIE BAUER, THE ENGINE COMPLETELY SHUTS OFF. SOMETIMES WHILE SITTING IDLE AND OTHER TIMES WHILE DRIVING 70 MPH ON THE INTERSTATE. TONIGHT, WITHIN 1 HOUR THIS HAPPENED ABOUT 15 TIMES WHERE THE ENGINE CUT OFF, I LOST POWER STEERING, HAD TO ROLL OVER TO THE SHOULDER, TURN THE KEY OFF AND BAC…
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WHILE DRIVING MY 2006 FORD EXPEDITION EDDIE BAUER, THE ENGINE COMPLETELY SHUTS OFF. SOMETIMES WHILE SITTING IDLE AND OTHER TIMES WHILE DRIVING 70 MPH ON THE INTERSTATE. TONIGHT, WITHIN 1 HOUR THIS HAPPENED ABOUT 15 TIMES WHERE THE ENGINE CUT OFF, I LOST POWER STEERING, HAD TO ROLL OVER TO THE SHOULDER, TURN THE KEY OFF AND BACK ON TO RESTART...SOMETIMES IT WOULD TAKE UP TO 10 MINUTES TO RESTART. I WAS LUCKY WE WERE NOT HIT FROM BEHIND. I HAVE 2 KIDS IN CARSEATS STILL THAT COULD HAVE BEEN INJURED. RESEARCH ONLINE REVEALS THAT I AM NOT ALONE. THIS IS A VERY DANGEROUS DEFECT THAT COULD GET SOMEBODY KILLED. *TR
NHTSA ODI #10437417
50,500 miles · Mar 25, 2011
Vehicle Speed Control
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT WAS DRIVING 30 MPH WHEN THE VEHICLE STALLED WITHOUT WARNING. THE FAILURE WOULD RECUR SPORADICALLY WHEN TRAVELING AT VARIOUS SPEEDS. THE VEHICLE WAS ABLE TO BE RESTARTED AND WAS TAKEN TO THE DEALER WHO REPAIRED THE THROTTLE BODY AND MOTOR ASSEMBLY, STATING THAT THE VEHICLE …
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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT WAS DRIVING 30 MPH WHEN THE VEHICLE STALLED WITHOUT WARNING. THE FAILURE WOULD RECUR SPORADICALLY WHEN TRAVELING AT VARIOUS SPEEDS. THE VEHICLE WAS ABLE TO BE RESTARTED AND WAS TAKEN TO THE DEALER WHO REPAIRED THE THROTTLE BODY AND MOTOR ASSEMBLY, STATING THAT THE VEHICLE HAD ENGAGED IN FAIL-SAFE MODE. THE MANUFACTURER WAS CONTACTED AND A COMPLAINT WAS FILED BUT NO FURTHER ASSISTANCE WAS PROVIDED. THE CURRENT MILEAGE WAS APPROXIMATELY 51,000 AND THE FAILURE MILEAGE WAS APPROXIMATELY 50,500.
NHTSA ODI #10392883
102,000 miles · Mar 18, 2011
Vehicle Speed Control
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. WHILE DRIVING APPROXIMATELY 50 MPH, THE CONTACT STATED THAT THE FAIL SAFE MODE SYMBOL ILLUMINATED ON THE DASHBOARD AS THE VEHICLE STALLED. THE VEHICLE WAS TAKEN TO THE DEALER BUT THEY WERE UNABLE TO DUPLICATE THE FAILURE. A PRIVATE MECHANIC DIAGNOSED THE VEHICLE WITH A THROTTLE BODY F…
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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. WHILE DRIVING APPROXIMATELY 50 MPH, THE CONTACT STATED THAT THE FAIL SAFE MODE SYMBOL ILLUMINATED ON THE DASHBOARD AS THE VEHICLE STALLED. THE VEHICLE WAS TAKEN TO THE DEALER BUT THEY WERE UNABLE TO DUPLICATE THE FAILURE. A PRIVATE MECHANIC DIAGNOSED THE VEHICLE WITH A THROTTLE BODY FAILURE. THE CONTACT DID NOT INFORM THE MANUFACTURER NOR WAS THE VEHICLE REPAIRED. THE CURRENT AND FAILURE MILEAGE WAS 102,000.
NHTSA ODI #10392175
70,000 miles · Sep 10, 2010
Vehicle Speed Control
TL*THE CONTACT OWNS A 2006 FORD EXPEDITION. WHILE DRIVING APPROXIMATELY 70 MPH ALL OF THE INTERIOR AND EXTERIOR LIGHTS BEGAN TO DIM. THE RADIO SHUT OFF AND THE VEHICLE THEN STALLED. THE VEHICLE WAS TOWED HOME WHERE SHE REPLACED THE ALTERNATOR. APPROXIMATELY 5 MONTHS LATER THE FAILURE RECURRED. THE VEHICLE WAS TAKEN TO AN AUTHOR…
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TL*THE CONTACT OWNS A 2006 FORD EXPEDITION. WHILE DRIVING APPROXIMATELY 70 MPH ALL OF THE INTERIOR AND EXTERIOR LIGHTS BEGAN TO DIM. THE RADIO SHUT OFF AND THE VEHICLE THEN STALLED. THE VEHICLE WAS TOWED HOME WHERE SHE REPLACED THE ALTERNATOR. APPROXIMATELY 5 MONTHS LATER THE FAILURE RECURRED. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER WHERE THE STARTER WAS REPLACED. APPROXIMATELY 1 MONTH LATER THE FAILURE BEGAN TO INTERMITTENTLY RECUR. DURING ONE OF THE FAILURES THE CHECK ENGINE LIGHT ALSO BEGAN TO ILLUMINATE ON THE DASHBOARD. THE VEHICLE WAS TAKEN BACK TO AN AUTHORIZED DEALER WHERE SHE WAS INFORMED THE FAILURE WAS DUE TO THE THROTTLE BODY. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 70,000 AND THE CURRENT MILEAGE WAS 87,000. THE VIN WAS UNAVAILABLE.
NHTSA ODI #10354878
44,000 miles · Jul 29, 2010
Vehicle Speed Control
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT WAS DRIVING UNDER 20 MPH WHEN HE APPLIED THE BRAKES. THERE WAS AN INCREASE IN ENGINE RPMS AND THE VEHICLE ABNORMALLY ACCELERATED. THE BRAKE PEDAL WAS APPLIED WITH FORCE AND THE VEHICLE CONTINUED TO ACCELERATE. WHEN THE GEAR SELECTOR WAS SHIFTED INTO THE NEUTRAL POSITION, …
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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT WAS DRIVING UNDER 20 MPH WHEN HE APPLIED THE BRAKES. THERE WAS AN INCREASE IN ENGINE RPMS AND THE VEHICLE ABNORMALLY ACCELERATED. THE BRAKE PEDAL WAS APPLIED WITH FORCE AND THE VEHICLE CONTINUED TO ACCELERATE. WHEN THE GEAR SELECTOR WAS SHIFTED INTO THE NEUTRAL POSITION, THE VEHICLE CAME TO A COMPLETE STOP. THE ENGINE WAS TURNED OFF AND RESTARTED. THE VEHICLE WAS ABLE TO RESUME NORMAL OPERATIONS. THE CONTACT WAS IN THE PROCESS OF TAKING THE VEHICLE TO AN AUTHORIZED DEALER FOR DIAGNOSTIC TESTING. THE FAILURE MILEAGE WAS 44,000.
NHTSA ODI #10346046
80,000 miles · Jun 28, 2010
Vehicle Speed Control
TL* CONTACT OWNS A 2005 FORD EXPEDITION. THE CONTACT STATED WHILE DRIVING AT 50 MPH, THE VEHICLE SUDDENLY STALLED WITHOUT WARNING. THE CONTACT WAS ABLE TO RESTART THE VEHICLE BUT IT STALLED A SECOND TIME WITHIN SECONDS. THE VEHICLE WAS TOWED TO HIS RESIDENCE. THE CONTACT WAS ABLE TO LOCATE NUMEROUS COMPLAINTS REGARDING THE THRO…
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TL* CONTACT OWNS A 2005 FORD EXPEDITION. THE CONTACT STATED WHILE DRIVING AT 50 MPH, THE VEHICLE SUDDENLY STALLED WITHOUT WARNING. THE CONTACT WAS ABLE TO RESTART THE VEHICLE BUT IT STALLED A SECOND TIME WITHIN SECONDS. THE VEHICLE WAS TOWED TO HIS RESIDENCE. THE CONTACT WAS ABLE TO LOCATE NUMEROUS COMPLAINTS REGARDING THE THROTTLE CONTROL AND BELIEVED IT TO BE THE CAUSE OF THE FAILURE. THE VEHICLE WAS NOT TAKEN TO THE DEALER FOR DIAGNOSTIC TESTING OR REPAIRS. THE FAILURE MILEAGE WAS 80,000.
NHTSA ODI #10340416
83,968 miles · May 3, 2010
Engine And Engine CoolingVehicle Speed Control
DRIVING TO WORK VIA FREEWAY, HAD JUST REACHED THE BOTTOM OF A FREEWAY OFF-RAMP, AT A STOPLIGHT. LIGHT TURNED GREEN, HAD JUST STARTED TO GO AND THE "FAIL SAFE ENGINE MODE" LIGHT ON MY 2006 FORD EXPEDITION CAME ON THE DASHBOARD, WITHIN 5 SECONDS THE CAR TURNED OFF ON ITS OWN, LIKE TAKING THE KEY OUT OF THE IGNITION. HAD IT TOWED …
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DRIVING TO WORK VIA FREEWAY, HAD JUST REACHED THE BOTTOM OF A FREEWAY OFF-RAMP, AT A STOPLIGHT. LIGHT TURNED GREEN, HAD JUST STARTED TO GO AND THE "FAIL SAFE ENGINE MODE" LIGHT ON MY 2006 FORD EXPEDITION CAME ON THE DASHBOARD, WITHIN 5 SECONDS THE CAR TURNED OFF ON ITS OWN, LIKE TAKING THE KEY OUT OF THE IGNITION. HAD IT TOWED TO A FORD DEALERSHIP, THEY RAN DIAGNOSTICS, SAID THE THROTTLE BODY ASSEMBLY NEEDED REPLACING. I LOOKED ON THE INTERNET, GOOGLING "FAIL SAFE ENGINE MODE" AND "FORD" AND FOUND THIS TO BE A COMMON PROBLEM. ASKED WHY IT'S NOT A RECALL ITEM OR HAS A TECHNICAL BULLETIN WITH SO MANY CASES OF IT, PLUS IT'S VERY DANGEROUS. MANY IN THEIR INTERNET POSTINGS SAID THE PROBLEM COMES BACK. DEALERSHIP SAID TO CONTACT FORD CORPORATE, OPENED A CUDL CASE FOR ME TO REQUEST REIMBURSEMENT. WROTE A LETTER TO FORD CORPORATE, INCLUDED INTERNET LINKS TO ALL THE POSTINGS OF OTHER PEOPLE HAVING THE SAME PROBLEM, ASKED FOR $480.35 REIMBURSEMENT, ALSO ASKED WHAT THEY ARE DOING ABOUT THIS DANGEROUS SITUATION WITH THE THROTTLE BODY ASSEMBLY. FORD CORPORATE SEND ME A LETTER BACK, SIMPLY SAID I'M PAST WARRANTY AND UNABLE TO PROVIDE REIMBURSEMENT. THEY DID NOT REPLY REGARDING MY QUESTION ABOUT WHAT'S BEING DONE ABOUT THIS DANGEROUS PROBLEM. *TR
NHTSA ODI #10328713
10,000 miles · Feb 1, 2010
Vehicle Speed Control
TL*THE CONTACT OWNS A 2006 FORD EXPEDITION WHICH WAS PURCHASED BRAND NEW. WHILE STEPPING ON THE ACCELERATOR PEDAL AT ANY SPEED INCLUDING APPROXIMATELY 25 MPH, THE PEDAL BECAME STUCK IN THE OPEN THROTTLE POSITION. THE VEHICLE WAS TAKEN TO THE DEALER; HOWEVER, THE FAILURE COULD NOT BE DUPLICATED. THE FAILURE WAS ALSO REPORTED TO …
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TL*THE CONTACT OWNS A 2006 FORD EXPEDITION WHICH WAS PURCHASED BRAND NEW. WHILE STEPPING ON THE ACCELERATOR PEDAL AT ANY SPEED INCLUDING APPROXIMATELY 25 MPH, THE PEDAL BECAME STUCK IN THE OPEN THROTTLE POSITION. THE VEHICLE WAS TAKEN TO THE DEALER; HOWEVER, THE FAILURE COULD NOT BE DUPLICATED. THE FAILURE WAS ALSO REPORTED TO THE MANUFACTURER. THERE WERE NO RECALLS. NO REPAIRS WERE MADE TO DATE. THE FAILURE MILEAGE WAS 10,000 AND THE CURRENT MILEAGE WAS 45,000.
NHTSA ODI #10303599
NHTSA investigations
1PE08070 · Steel Wheel Fracture
Opened Dec 9, 2008 · Closed Apr 15, 2009
Status: closed (inferred from source dates) · Wheels; Wheels:rim
FORD SPECIAL SERVICE VEHICLE (SSV) EXPEDITIONS USE A STEEL FULL FACE WHEEL DESIGN SIMILAR TO THAT INVESTIGATED IN PE03009, RQ04007, EA04034 (CROWN VICTORIA POLICE INTERCEPTOR) AND PE03026 (GM PICKUPS AND SUVS).A TOTAL OF 8,251 SSVS (2.2% OF TOTAL PRODUCTION) WERE PRODUCED WITHIN MODEL YEARS 2004-2006 AND SOLD PRIMARILY FOR USE BY STATE, FEDERAL, AND MUNICIPAL LAW ENFORCEMENT (LE) AGENCIES.FORD STIPULATES THAT THE SUBJECT VEHICLES ARE NOT SUITABLE FOR HIGH SPEED OR PURSUIT OPERATIONS AND ALSO IDENTIFIED A 2004 NATIONAL INSTITUTE FOR JUSTICE VEHICLE EVALUATION REPORT WHICH ALSO ACKNOWLEDGES THIS LIMITATION. THE FULL FACE WHEEL IS FABRICATED FROM TWO PIECES: A STAMPED OUTER WHEEL DISC AND A FORMED RIM.THE TWO PIECES, WHICH TOGETHER COMPRISE THE OUTER BEAD SEAT, ARE JOINED TOGETHER WITH A CIRCUMFERENTIAL WELD.A CYCLIC BENDING MOMENT OCCURS IN THE OUTER BEAD SEAT AREA AS THE WHEEL ROTATES, RESULTING IN FATIGUE STRESSES IN THE WELD'S HEAT AFFECTED ZONE THAT CAN LEAD TO FRACTURING (CRACKING) OF THE RIM MATERIAL.BECAUSE THE FAILURE OCCURS UNDER THE OUTBOARD TIRE BEAD, AIR LEAKAGE MAY NOT READILY OCCUR WHEN THE RIM CRACKS, DEPENDENT ON HOW WELL THE BEAD SEALS ON THE RIM.IF MULTIPLE CRACKS GROW UNDETECTED AND SUDDENLY JOIN INTO A SINGLE LARGE CRACK, THE WHEEL'S STRUCTURE CAN BECOME COMPROMISED LEADING TO RAPID AIR LOSS.A RAPID AIR LOSS, ESPECIALLY AT HIGHER SPEED, MAY LEAD TO A CRASH. FORD RESPONDED TO ODI'S JANUARY 5, 2009 INFORMATION REQUEST (IR) ON FEBRUARY 24.FORD'S RESPONSE ACKNOWLEDGES A NUMBER OF WHEEL FRACTURES ON THE SSVS.HOWEVER, BASED ON ITS ASSESSMENT OF THE PERTINENT FACTORS, IT CONCLUDES THAT THE CONDITION DOES NOT REPRESENT AN UNREASONABLE RISK TO SAFETY.THE LACK OF REPORTS OF RAPID AIR LOSS, NO ALLEGED CRASHES, AND THEIR ASSESSMENT THAT A CRACKED WHEEL CAN BE DETECTED THROUGH SLOW, REPEATED AIR LOSS OR VIBRATION, WERE THE BASES FOR FORD'S CONCLUSION.FORD DISCUSSES THE RESULTS OF A STUDY IT PERFORMED ON WHEELS RETURNED FROM LE FIELD USE, DESIGN REVISIONS IT MADE TO THE SUBJECT WHEEL, AND THE OUTCOME OF DURABILITY TESTING IT CONDUCTED ON THE OLD AND NEW WHEEL DESIGNS. THE COUNTS SHOWN ABOVE INCLUDE A DUPLICATE ODI AND FORD REPORT; THE FORD COUNTS ARE UNIQUE VEHICLES ALLEGING WHEEL FRACTURE(S).SOME WARRANTY CLAIMS INVOLVED MORE THAN ONE WHEEL REPLACEMENT.ALTHOUGH THE SUBJECT VEHICLES HAVE BEEN IN SERVICE FOR A LONGER PERIOD OF TIME THAN VEHICLES INVESTIGATED IN THE PREVIOUS INVESTIGATIONS OF TWO-PIECE WHEEL FRACTURE, ODI DID NOT IDENTIFY ANY ALLEGATIONS OF CRASHES, RAPID AIR LOSS EVENTS DUE TO WHEEL FRACTURES OR ALLEGATIONS OF EFFECTS ON VEHICLE CONTROL OR STABILITY, AS WERE THE CASES IN PAST INVESTIGATIONS WHERE SAFETY RECALLS WERE CONDUCTED TO REPLACE AFFECTED WHEELS.THE AGENCY AGREES THAT THE SSV IS NOT SUITABLE FOR PURSUIT OR HIGH SPEED USAGE, REDUCING THE POTENTIAL FOR CRASHES OR LOSS OF CONTROL INCIDENTS TO BE CAUSED BY THE ALLEGED DEFECT. FORD IMPLEMENTED A 'SHOT PEENING' PROCESS IN JUNE 2006 WHICH REDUCED THE WHEEL'S SURFACE STRESS AND SIGNIFICANTLY IMPROVED ITS DURABILITY, AND ODI IS UNAWARE OF ANY FAILURES OF SHOT PEENED WHEELS (SERVICE PART NUMBER 7L1Z-1015-B).FORD'S TESTING SHOWED A SLIGHTLY REDUCED DURABILITY FOR THE NON-SHOT PEENED WHEELS WHEN 'LT' INSTEAD OF FORD APPROVED 'P' METRIC TYPE TIRES ARE USED. A SAFETY-RELATED DEFECT HAS NOT BEEN IDENTIFIED AT THIS TIME AND FURTHER USE OF AGENCY RESOURCES DOES NOT APPEAR TO BE WARRANTED.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST.THE AGENCY WILL TAKE FURTHER ACTION IF WARRANTED BY FURTHER C
Additional source detail variants (2)
Wheels
FORD SPECIAL SERVICE VEHICLE (SSV) EXPEDITIONS USE A STEEL FULL FACE WHEEL DESIGN SIMILAR TO THAT INVESTIGATED IN PE03009, RQ04007, EA04034 (CROWN VICTORIA POLICE INTERCEPTOR) AND PE03026 (GM PICKUPS AND SUVS).A TOTAL OF 8,251 SSVS (2.2% OF TOTAL PRODUCTION) WERE PRODUCED WITHIN MODEL YEARS 2004-2006 AND SOLD PRIMARILY FOR USE BY STATE, FEDERAL, AND MUNICIPAL LAW ENFORCEMENT (LE) AGENCIES.FORD STIPULATES THAT THE SUBJECT VEHICLES ARE NOT SUITABLE FOR HIGH SPEED OR PURSUIT OPERATIONS AND ALSO IDENTIFIED A 2004 NATIONAL INSTITUTE FOR JUSTICE VEHICLE EVALUATION REPORT WHICH ALSO ACKNOWLEDGES THIS LIMITATION. THE FULL FACE WHEEL IS FABRICATED FROM TWO PIECES: A STAMPED OUTER WHEEL DISC AND A FORMED RIM.THE TWO PIECES, WHICH TOGETHER COMPRISE THE OUTER BEAD SEAT, ARE JOINED TOGETHER WITH A CIRCUMFERENTIAL WELD.A CYCLIC BENDING MOMENT OCCURS IN THE OUTER BEAD SEAT AREA AS THE WHEEL ROTATES, RESULTING IN FATIGUE STRESSES IN THE WELD'S HEAT AFFECTED ZONE THAT CAN LEAD TO FRACTURING (CRACKING) OF THE RIM MATERIAL.BECAUSE THE FAILURE OCCURS UNDER THE OUTBOARD TIRE BEAD, AIR LEAKAGE MAY NOT READILY OCCUR WHEN THE RIM CRACKS, DEPENDENT ON HOW WELL THE BEAD SEALS ON THE RIM.IF MULTIPLE CRACKS GROW UNDETECTED AND SUDDENLY JOIN INTO A SINGLE LARGE CRACK, THE WHEEL'S STRUCTURE CAN BECOME COMPROMISED LEADING TO RAPID AIR LOSS.A RAPID AIR LOSS, ESPECIALLY AT HIGHER SPEED, MAY LEAD TO A CRASH. FORD RESPONDED TO ODI'S JANUARY 5, 2009 INFORMATION REQUEST (IR) ON FEBRUARY 24.FORD'S RESPONSE ACKNOWLEDGES A NUMBER OF WHEEL FRACTURES ON THE SSVS.HOWEVER, BASED ON ITS ASSESSMENT OF THE PERTINENT FACTORS, IT CONCLUDES THAT THE CONDITION DOES NOT REPRESENT AN UNREASONABLE RISK TO SAFETY.THE LACK OF REPORTS OF RAPID AIR LOSS, NO ALLEGED CRASHES, AND THEIR ASSESSMENT THAT A CRACKED WHEEL CAN BE DETECTED THROUGH SLOW, REPEATED AIR LOSS OR VIBRATION, WERE THE BASES FOR FORD'S CONCLUSION.FORD DISCUSSES THE RESULTS OF A STUDY IT PERFORMED ON WHEELS RETURNED FROM LE FIELD USE, DESIGN REVISIONS IT MADE TO THE SUBJECT WHEEL, AND THE OUTCOME OF DURABILITY TESTING IT CONDUCTED ON THE OLD AND NEW WHEEL DESIGNS. THE COUNTS SHOWN ABOVE INCLUDE A DUPLICATE ODI AND FORD REPORT; THE FORD COUNTS ARE UNIQUE VEHICLES ALLEGING WHEEL FRACTURE(S).SOME WARRANTY CLAIMS INVOLVED MORE THAN ONE WHEEL REPLACEMENT.ALTHOUGH THE SUBJECT VEHICLES HAVE BEEN IN SERVICE FOR A LONGER PERIOD OF TIME THAN VEHICLES INVESTIGATED IN THE PREVIOUS INVESTIGATIONS OF TWO-PIECE WHEEL FRACTURE, ODI DID NOT IDENTIFY ANY ALLEGATIONS OF CRASHES, RAPID AIR LOSS EVENTS DUE TO WHEEL FRACTURES OR ALLEGATIONS OF EFFECTS ON VEHICLE CONTROL OR STABILITY, AS WERE THE CASES IN PAST INVESTIGATIONS WHERE SAFETY RECALLS WERE CONDUCTED TO REPLACE AFFECTED WHEELS.THE AGENCY AGREES THAT THE SSV IS NOT SUITABLE FOR PURSUIT OR HIGH SPEED USAGE, REDUCING THE POTENTIAL FOR CRASHES OR LOSS OF CONTROL INCIDENTS TO BE CAUSED BY THE ALLEGED DEFECT. FORD IMPLEMENTED A 'SHOT PEENING' PROCESS IN JUNE 2006 WHICH REDUCED THE WHEEL'S SURFACE STRESS AND SIGNIFICANTLY IMPROVED ITS DURABILITY, AND ODI IS UNAWARE OF ANY FAILURES OF SHOT PEENED WHEELS (SERVICE PART NUMBER 7L1Z-1015-B).FORD'S TESTING SHOWED A SLIGHTLY REDUCED DURABILITY FOR THE NON-SHOT PEENED WHEELS WHEN 'LT' INSTEAD OF FORD APPROVED 'P' METRIC TYPE TIRES ARE USED. A SAFETY-RELATED DEFECT HAS NOT BEEN IDENTIFIED AT THIS TIME AND FURTHER USE OF AGENCY RESOURCES DOES NOT APPEAR TO BE WARRANTED.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST.THE AGENCY WILL TAKE FURTHER ACTION IF WARRANTED BY FURTHER C
Wheels:rim
FORD SPECIAL SERVICE VEHICLE (SSV) EXPEDITIONS USE A STEEL FULL FACE WHEEL DESIGN SIMILAR TO THAT INVESTIGATED IN PE03009, RQ04007, EA04034 (CROWN VICTORIA POLICE INTERCEPTOR) AND PE03026 (GM PICKUPS AND SUVS).A TOTAL OF 8,251 SSVS (2.2% OF TOTAL PRODUCTION) WERE PRODUCED WITHIN MODEL YEARS 2004-2006 AND SOLD PRIMARILY FOR USE BY STATE, FEDERAL, AND MUNICIPAL LAW ENFORCEMENT (LE) AGENCIES.FORD STIPULATES THAT THE SUBJECT VEHICLES ARE NOT SUITABLE FOR HIGH SPEED OR PURSUIT OPERATIONS AND ALSO IDENTIFIED A 2004 NATIONAL INSTITUTE FOR JUSTICE VEHICLE EVALUATION REPORT WHICH ALSO ACKNOWLEDGES THIS LIMITATION. THE FULL FACE WHEEL IS FABRICATED FROM TWO PIECES: A STAMPED OUTER WHEEL DISC AND A FORMED RIM.THE TWO PIECES, WHICH TOGETHER COMPRISE THE OUTER BEAD SEAT, ARE JOINED TOGETHER WITH A CIRCUMFERENTIAL WELD.A CYCLIC BENDING MOMENT OCCURS IN THE OUTER BEAD SEAT AREA AS THE WHEEL ROTATES, RESULTING IN FATIGUE STRESSES IN THE WELD'S HEAT AFFECTED ZONE THAT CAN LEAD TO FRACTURING (CRACKING) OF THE RIM MATERIAL.BECAUSE THE FAILURE OCCURS UNDER THE OUTBOARD TIRE BEAD, AIR LEAKAGE MAY NOT READILY OCCUR WHEN THE RIM CRACKS, DEPENDENT ON HOW WELL THE BEAD SEALS ON THE RIM.IF MULTIPLE CRACKS GROW UNDETECTED AND SUDDENLY JOIN INTO A SINGLE LARGE CRACK, THE WHEEL'S STRUCTURE CAN BECOME COMPROMISED LEADING TO RAPID AIR LOSS.A RAPID AIR LOSS, ESPECIALLY AT HIGHER SPEED, MAY LEAD TO A CRASH. FORD RESPONDED TO ODI'S JANUARY 5, 2009 INFORMATION REQUEST (IR) ON FEBRUARY 24.FORD'S RESPONSE ACKNOWLEDGES A NUMBER OF WHEEL FRACTURES ON THE SSVS.HOWEVER, BASED ON ITS ASSESSMENT OF THE PERTINENT FACTORS, IT CONCLUDES THAT THE CONDITION DOES NOT REPRESENT AN UNREASONABLE RISK TO SAFETY.THE LACK OF REPORTS OF RAPID AIR LOSS, NO ALLEGED CRASHES, AND THEIR ASSESSMENT THAT A CRACKED WHEEL CAN BE DETECTED THROUGH SLOW, REPEATED AIR LOSS OR VIBRATION, WERE THE BASES FOR FORD'S CONCLUSION.FORD DISCUSSES THE RESULTS OF A STUDY IT PERFORMED ON WHEELS RETURNED FROM LE FIELD USE, DESIGN REVISIONS IT MADE TO THE SUBJECT WHEEL, AND THE OUTCOME OF DURABILITY TESTING IT CONDUCTED ON THE OLD AND NEW WHEEL DESIGNS. THE COUNTS SHOWN ABOVE INCLUDE A DUPLICATE ODI AND FORD REPORT; THE FORD COUNTS ARE UNIQUE VEHICLES ALLEGING WHEEL FRACTURE(S).SOME WARRANTY CLAIMS INVOLVED MORE THAN ONE WHEEL REPLACEMENT.ALTHOUGH THE SUBJECT VEHICLES HAVE BEEN IN SERVICE FOR A LONGER PERIOD OF TIME THAN VEHICLES INVESTIGATED IN THE PREVIOUS INVESTIGATIONS OF TWO-PIECE WHEEL FRACTURE, ODI DID NOT IDENTIFY ANY ALLEGATIONS OF CRASHES, RAPID AIR LOSS EVENTS DUE TO WHEEL FRACTURES OR ALLEGATIONS OF EFFECTS ON VEHICLE CONTROL OR STABILITY, AS WERE THE CASES IN PAST INVESTIGATIONS WHERE SAFETY RECALLS WERE CONDUCTED TO REPLACE AFFECTED WHEELS.THE AGENCY AGREES THAT THE SSV IS NOT SUITABLE FOR PURSUIT OR HIGH SPEED USAGE, REDUCING THE POTENTIAL FOR CRASHES OR LOSS OF CONTROL INCIDENTS TO BE CAUSED BY THE ALLEGED DEFECT. FORD IMPLEMENTED A 'SHOT PEENING' PROCESS IN JUNE 2006 WHICH REDUCED THE WHEEL'S SURFACE STRESS AND SIGNIFICANTLY IMPROVED ITS DURABILITY, AND ODI IS UNAWARE OF ANY FAILURES OF SHOT PEENED WHEELS (SERVICE PART NUMBER 7L1Z-1015-B).FORD'S TESTING SHOWED A SLIGHTLY REDUCED DURABILITY FOR THE NON-SHOT PEENED WHEELS WHEN 'LT' INSTEAD OF FORD APPROVED 'P' METRIC TYPE TIRES ARE USED. A SAFETY-RELATED DEFECT HAS NOT BEEN IDENTIFIED AT THIS TIME AND FURTHER USE OF AGENCY RESOURCES DOES NOT APPEAR TO BE WARRANTED.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST.THE AGENCY WILL TAKE FURTHER ACTION IF WARRANTED BY FURTHER C
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