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
NHTSA ODI #10478584
120,000 miles · Apr 19, 2010
Wheels
2006 FORD EXPEDITION (LAW ENFORCEMENT PACKAGE) WITH STEEL WHEELS AND APPROX. 120,000 MILES; WHEEL SEPARATION (CRACKED ALONG WELD). PRIOR TO THE FAILURE, THIS VEHICLE WAS USED DAILY FOR ROUTINE LAW ENFORCEMENT PATROL DUTIES. WE HAVE HAD THIS ISSUE ON SEVERAL 2006 EXPEDITIONS. UPON LEARNING OF THE POTENTIAL FOR THE WHEEL FAILUR…
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2006 FORD EXPEDITION (LAW ENFORCEMENT PACKAGE) WITH STEEL WHEELS AND APPROX. 120,000 MILES; WHEEL SEPARATION (CRACKED ALONG WELD). PRIOR TO THE FAILURE, THIS VEHICLE WAS USED DAILY FOR ROUTINE LAW ENFORCEMENT PATROL DUTIES. WE HAVE HAD THIS ISSUE ON SEVERAL 2006 EXPEDITIONS. UPON LEARNING OF THE POTENTIAL FOR THE WHEEL FAILURE, WE HAVE IMPLEMENTED PROCEDURES TO INSPECT THE WHEELS FOR CRACKS AND OTHER DAMAGE REGULARLY. IN ALL CASES, THERE HAVE BEEN NO OBVIOUS WARNING SIGNS BEFORE FAILURE. THIS PROBLEM WAS DISCOVERED WHEN THE OFFICER NOTICED A FLAT TIRE PRIOR TO STARTING HIS SHIFT FOR THE DAY. UPON FINDING THE CRACKED WHEEL A NEW REPLACEMENT WHEEL WAS INSTALLED ON THE VEHICLE. *TR
NHTSA ODI #10326438
88,607 miles · Feb 17, 2010
Wheels
TIRE RIM FAILURE ON A 2006 FORD EXPEDITION USED BY A U.S. FOREST SERVICE LAW ENFORCEMENT OFFICER. THE VEHICLE CURRENTLY HAS 88,607 MILES. AFTER REPORT 10307412, WE COMPLETED A FLEET WIDE INSPECTION OF FORD VEHICLES WITH STEEL WHEELS. THIS IS THE 4TH INCIDENT OF THIS NATURE TO OCCUR WITHIN 2 YEARS. THE OTHER 3 TIMES THE FAILURE O…
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TIRE RIM FAILURE ON A 2006 FORD EXPEDITION USED BY A U.S. FOREST SERVICE LAW ENFORCEMENT OFFICER. THE VEHICLE CURRENTLY HAS 88,607 MILES. AFTER REPORT 10307412, WE COMPLETED A FLEET WIDE INSPECTION OF FORD VEHICLES WITH STEEL WHEELS. THIS IS THE 4TH INCIDENT OF THIS NATURE TO OCCUR WITHIN 2 YEARS. THE OTHER 3 TIMES THE FAILURE OCCURRED ON OTHER FORD EXPEDITIONS. REPORTS WERE FILED HERE. SEE COMPLAINT 10286279, 10307412. BASED ON PRIOR 3 FAILURES, A UNIT-08 FOREST WIDE INSPECTION OF FORD VEHICLES WITH STEEL WHEELS IS UNDERWAY. I CURRENTLY HAVE TWO RIMS WITH TYPICAL RIM FAILURE AT THE BEAD FACE WELD FROM TWO DIFFERENT VEHICLES. PLEASE ADVISE IF PHOTO DOCUMENTATION IS REQUIRED. AFTER INSPECTION BY FORD TECHNICIAN, ALL 4 WHEELS WERE REPLACED. RECOMMEND FORD INITIATE A RECALL ON STEEL WHEEL FOR CRACK INSPECTION ASSOCIATED WITH 2003 AND NEWER FORD VEHICLES WITH STEEL WHEELS. *TR
NHTSA ODI #10311415
71,000 miles · Feb 8, 2010
Wheels
TIRE RIM FAILURE ON A 2006 FORD EXPEDITION USED BY A U.S. FOREST SERVICE LAW ENFORCEMENT OFFICER. THE VEHICLE CURRENTLY HAS 71,000 MILES, THIS IS THE 3RD INCIDENT OF THIS NATURE TO OCCUR WITH 2 YEARS. THE OTHER 2 TIMES THE FAILURE OCCURRED ON ANOTHER FORD EXPEDITION. UNKNOWN IF REPORTS WERE FILED HERE. SEE COMPLAINT 10286279. …
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TIRE RIM FAILURE ON A 2006 FORD EXPEDITION USED BY A U.S. FOREST SERVICE LAW ENFORCEMENT OFFICER. THE VEHICLE CURRENTLY HAS 71,000 MILES, THIS IS THE 3RD INCIDENT OF THIS NATURE TO OCCUR WITH 2 YEARS. THE OTHER 2 TIMES THE FAILURE OCCURRED ON ANOTHER FORD EXPEDITION. UNKNOWN IF REPORTS WERE FILED HERE. SEE COMPLAINT 10286279. BASED ON PRIOR 2 FAILURES, A REGION WIDE INSPECTION OF FORD VEHICLES WITH STEEL WHEELS IS UNDERWAY. IF A PHOTO IS NEEDED, I HAVE THAT AS WELL
NHTSA ODI #10307412
73,400 miles · Dec 21, 2009
Wheels
FORD EXPEDITION STEEL WHEEL RIM FAILURE. *TR
NHTSA ODI #10296524
90,200 miles · Oct 5, 2009
Wheels
TIRE RIM FAILURE ON A 2006 FORD EXPEDITION USED BY A U.S. FOREST SERVICE LAW ENFORCEMENT OFFICER. THE VEHICLE CURRENTLY HAS 90,200 MILES, THIS IS THE 4TH INCIDENT OF THIS NATURE TO OCCUR. THE OTHER 3 TIMES THE FAILURE OCCURRED ON ANOTHER FORD EXPEDITION AND REPORTS WERE FILED HERE WITH THE NHTSA. *TR
NHTSA ODI #10286279
88,930 miles · Mar 12, 2009
Wheels
A WHEEL SEPARATED ON A 2006 FORD EXPEDITION. WE REPLACED THE WHEEL AND I HAVE THE ORIGINAL THAT FAILED. *TR
NHTSA ODI #10261663
55,000 miles · Oct 30, 2008
Wheels
A 17" TIRE RIM ON A 2006 FORD EXPEDITION HAS FAILED FOR THE SECOND TIME. THE FIRST FAILED RIM WAS REPLACED BY FORD MOTOR CO. WITH A NEW RIM AND NOW ONLY A COUPLE OF MONTHS LATER THIS SECOND RIM HAS FAILED. THE WELD HAS FAILED ON THE RIM CAUSING SEPARATION AND A SERIOUS SAFETY HAZARD FOR ANY VEHICLE OCCUPANTS. *TR
NHTSA ODI #10247221
45,000 miles · Aug 14, 2008
Wheels
THE 17" STEEL TIRE RIM ON THE 2006 FORD EXPEDITION HAD SPLIT. *TR
NHTSA ODI #10238153
25,707 miles · Mar 5, 2008
Wheels
VEHICLE VIBRATION, SLOW LEAK OF TIRE PRESSURE. NEED FOR REPAIR INDICATED A WHEEL FAILURE WITH 25% TO 50% OF OUTER RIM CRACKING AWAY FROM WHEEL. VEHICLES ARE FORD EXPEDITIONS ONE A MODEL YR 2004 AND THE OTHER A MODEL YEAR 2006. USED IN LAW ENFORCEMENT. LOCAL FORD DEALERSHIP CONTACTED. *TR
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.
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
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