NHTSA owner reports · September 18, 2026 snapshot.
What owners actually said
299 reports70,000 miles · Jan 3, 2014
Engine
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT THE VEHICLE WOULD ENGAGE INTO SAFE MODE WHEN STARTED, CAUSING THE VEHICLE TO STALL. THE FAILURE WAS RECURRING OVER A THREE YEAR SPAN. THE VEHICLE WAS TAKEN TO A DEALER AND REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE PROBLEM. THE APPROXIMATE FAILURE WAS 70,…
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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT THE VEHICLE WOULD ENGAGE INTO SAFE MODE WHEN STARTED, CAUSING THE VEHICLE TO STALL. THE FAILURE WAS RECURRING OVER A THREE YEAR SPAN. THE VEHICLE WAS TAKEN TO A DEALER AND REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE PROBLEM. THE APPROXIMATE FAILURE WAS 70,000.
NHTSA ODI #10558303
125,000 miles · Dec 2, 2013
Engine
WHILE DRIVING APPROXIMATELY 35 KPH MY ABS LIGHT CAME ON FOLLOWED BY THE BRAKE LIGHT THEN THE AIRBAG LIGHT. (CHECK ENGINE NEVER GOES OFF. REPLACE ALL PLUGS AND COILS. REPLACE OF SENSORS AND SEVERAL FUSES.) THE HEADLIGHTS BEGIN TO FLASH OFF AND ON THEN TRUCK STARTED SPUTTERING. THE FUEL LIGHT WENT FROM 3/4 TANK TO E. I PULLED INTO…
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WHILE DRIVING APPROXIMATELY 35 KPH MY ABS LIGHT CAME ON FOLLOWED BY THE BRAKE LIGHT THEN THE AIRBAG LIGHT. (CHECK ENGINE NEVER GOES OFF. REPLACE ALL PLUGS AND COILS. REPLACE OF SENSORS AND SEVERAL FUSES.) THE HEADLIGHTS BEGIN TO FLASH OFF AND ON THEN TRUCK STARTED SPUTTERING. THE FUEL LIGHT WENT FROM 3/4 TANK TO E. I PULLED INTO SHOPPING CENTER PLACED IT IN PARK. WENT TO PUT IT BACK IN DRIVE AND COULDN'T SOMETHING WAS DRAINING BATTERY THAT IS ONLY 3 MONTHS OLD. DON'T KNOW RESOLUTION BUT TIRED OF THIS TRUCK! IT IS RIDICULOUS THAT THIS TRUCK HAS SO MANY REPEAT ISSUES AND NO RECALL. FORD NEEDS TO BE SUED. I DAILY HAVE TO TURN ON MY HAZARDS AND RESTART CAR BECAUSE IT SPONTANEOUSLY GOES INTO LIMP MODE, ESPECIALLY IN TRAFFIC. *TR
NHTSA ODI #10554452
82,000 miles · Nov 21, 2013
Engine
DRIVING AT 25MPH THE VEHICLE ENGINE SHUT DOWN AND WENT INTO FAILSAFE MODE, POWER STEERING ALSO DISABLED CAUSING A VERY DANGEROUS SITUATION TRYING TO STEER THE CAR FROM TRAFFIC TO A SAFE AREA WITHOUT ASSISTED STEERING. THIS PROBLEM HAS OCCURRED SEVERAL TIMES OVER THE PAST 2 YEARS AND USUALLY IN COLDER WEATHER. LAST TIME IT HAPPEN…
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DRIVING AT 25MPH THE VEHICLE ENGINE SHUT DOWN AND WENT INTO FAILSAFE MODE, POWER STEERING ALSO DISABLED CAUSING A VERY DANGEROUS SITUATION TRYING TO STEER THE CAR FROM TRAFFIC TO A SAFE AREA WITHOUT ASSISTED STEERING. THIS PROBLEM HAS OCCURRED SEVERAL TIMES OVER THE PAST 2 YEARS AND USUALLY IN COLDER WEATHER. LAST TIME IT HAPPENED WAS ON A MAIN HIGHWAY BUT LUCKILY I WAS ALONE WITHOUT MY FAMILY AND IN THE INSIDE LANE SO I WAS ABLE TO PULL OVER THANKFULLY IT DIDN'T HAPPEN IN THE OVERTAKING LANE AS THERE IS NO TIME TO SAFELY CHANGE LANES WHEN IT SHUTS DOWN. SURPRISED THERE HAS BEEN NO FATALITIES DUE TO THIS AS IT IS A COMMON PROBLEM WITH 2006 FORD TRUCKS. *TR
NHTSA ODI #10553237
60,000 miles · Nov 7, 2013
Engine
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING BETWEEN 45 TO 50 MPH, THE VEHICLE STALLED AND THE ENGINE FAIL SAFE LIGHT ILLUMINATED. THE CONTACT WAS ABLE TO COAST TO THE SHOULDER WHERE THE VEHICLE WAS RESTARTED. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER WHO STATED THAT THE THROTTLE BODY W…
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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING BETWEEN 45 TO 50 MPH, THE VEHICLE STALLED AND THE ENGINE FAIL SAFE LIGHT ILLUMINATED. THE CONTACT WAS ABLE TO COAST TO THE SHOULDER WHERE THE VEHICLE WAS RESTARTED. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER WHO STATED THAT THE THROTTLE BODY WAS NOT OPENING AND CLOSING CORRECTLY. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 60,000 AND THE CURRENT MILEAGE WAS 75,000.
NHTSA ODI #10551251
110,000 miles · Oct 21, 2013
Engine
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING 30 MPH, THE FAIL SAFETY ENGINE WARNING LIGHT ILLUMINATED AS THE VEHICLE STALLED. THE FAILURE WAS RECURRING. THE VEHICLE WAS NEITHER DIAGNOSED NOR REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED. THE FAILURE MILEAGE WAS 110,000.
NHTSA ODI #10548694
114,000 miles · Oct 15, 2013
Electrical SystemEngineVehicle Speed Control
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
NHTSA ODI #10547909
128,000 miles · Aug 6, 2013
Electrical SystemElectronic Stability Control (esc)Engine
LEMON! 2006 FORD EXPEDITION BEGINNING OF JUNE IT STARTED "BOGGING" DOWN WHILE DRIVING. WE TOOK IT TO AUTOZONE, MISFIRE. TOOK IT TO A MECHANIC WE KNOW AND HE TOLD US THE CODES SHOWED 6,7,8 SPARKPLUGS. TRYING TO SAVE $.THIS HELPED A LITTLE, STARTED DOING IT AGAIN BUT WORSE, THIS TIME IT WAS DECELERATING WE WERE GOING 75 & CHECK EN…
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LEMON! 2006 FORD EXPEDITION BEGINNING OF JUNE IT STARTED "BOGGING" DOWN WHILE DRIVING. WE TOOK IT TO AUTOZONE, MISFIRE. TOOK IT TO A MECHANIC WE KNOW AND HE TOLD US THE CODES SHOWED 6,7,8 SPARKPLUGS. TRYING TO SAVE $.THIS HELPED A LITTLE, STARTED DOING IT AGAIN BUT WORSE, THIS TIME IT WAS DECELERATING WE WERE GOING 75 & CHECK ENGINE LIGHT STARTED FLASHING & BOGGED DOWN TO 50 ON THE HWY ALMOST CAUSE SEVERAL WRECKS AS I TRIED TO PULL OVER TO THE SIDE (WITH MY KIDS IN THE CAR) TOOK IT INTO THE MECHANIC & OTHER SPARK PLUGS COIL PACKS & 1 INJECTOR GOT IT FIXED PICKED IT UP & DIDN'T EVEN GET DOWN THE ROAD & IT DID IT AGAIN.THIS TIME CHECK ENGINE LIGHT WENT OFF AFTER FLASHING.TOOK IT BACK TO HIM & NO CODES COULDN'T FIND ANYTHING.WENT HM & ALMOST GOT IN A WRECK AGAIN! IT DECELERATE TO 45 AFTER GOING 70. WE WENT HM, NEXT MORNING GOING TO TAKE IT BACK TO HIM AGAIN!! WHILE DRIVING, A/C TURNED OFF, DOOR SENSOR ALARM FAIL POPPED UP, ANOTHER SENSOR FAIL, &PULLED OVER PUT IN PARK & WOULDN'T COME OUT OF PARK.CALLED MECHANIC,AFTER SO MANY LOOK OVERS THINKING IT WAS PCM, SECURITY MODULE, HE GIVES UP AFTER 2 WKS OF WORKING ON IT.WE GET IT HM & START LOOKING ON HERE & FIND SO MUCH ABOUT THIS LIKE ITS GOING IN SAFE FAIL MODE WITHOUT SHUTTING OFF. START LOOKING AT ALL THE OTHER FORUMS & THIS YR MODEL HAD 362 COMPLAINS ON ANOTHER SITE & MANY ON HERE, SEVERAL OF THIS SAME DEAL.WE STARTED WITH FUSES #5 BLOWN, CHANGE BLOWS IMMEDIATELY, CHANGE AGAIN BLOWS AGAIN. START CHASING WIRES, CHANGE AGAIN STARTS UP.OKAY GREAT!!! NOW ROUGH IDLE, WAY BAD WHO CARES IT STARTS! DRIVE IT TO WORK, WE DESPERATELY NEED MY CAR & FORD CANT GET TO IT FOR 1 1/2 MONTHS.STARTS STALLING WHILE DRIVING AGAIN A/C SHUTS OFF AND SLOWS DOWN. FORD NEEDS TO FIX THIS BEFORE IT KILLS SOMEONE! THIS IS A MAJOR DEFECT THAT WILL KILL! I HAVE FOUND THIS SAME ISSUE ON THIS SAME SITE A LOT! WHY ISN'T ANYTHING BEING DONE? HELP!!!!!!!!! *TR
NHTSA ODI #10533790
93,000 miles · Jul 3, 2013
Engine And Engine Cooling
I BELIEVE THAT FORD EXPEDITIONS FROM YEARS 2003 - 2006 HAVE A SERIOUS DEFECT. I AM EXPERIENCING RADIATOR SUPPORT MOUNT ROT. MY MECHANIC SAYS THIS SHOULD NOT BE OCCURRING ON A VEHICLE THAT IS ONLY 6 YEARS OLD. I HAVE DONE SOME RESEARCH AND HAVE READ ON THE FORD EXPEDITION FORUM THAT MANY EXPEDITION DRIVERS ARE NOW FINDING THIS…
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I BELIEVE THAT FORD EXPEDITIONS FROM YEARS 2003 - 2006 HAVE A SERIOUS DEFECT. I AM EXPERIENCING RADIATOR SUPPORT MOUNT ROT. MY MECHANIC SAYS THIS SHOULD NOT BE OCCURRING ON A VEHICLE THAT IS ONLY 6 YEARS OLD. I HAVE DONE SOME RESEARCH AND HAVE READ ON THE FORD EXPEDITION FORUM THAT MANY EXPEDITION DRIVERS ARE NOW FINDING THIS TO BE THE CASE WITH THEIR VEHICLES AS WELL. I SERIOUSLY BELIEVE A RECALL SHOULD BE IN PLACE TO ADDRESS THIS PROBLEM. THE A/C CONDENSER IS NOW FALLING THROUGH AND THE BODY MOUNTS ARE BEING COMPROMISED. *TR
NHTSA ODI #10523121
101,000 miles · Jun 17, 2013
Engine
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED WHILE DRIVING 55 MPH SHE ATTEMPTED TO ACCELERATE THE VEHICLE AND IT BEGAN TO LUNGE AND HESITATE. THE VEHICLE ALSO STALLED. THE FAILURE RECURRED NUMEROUS TIMES. THE VEHICLE WAS NOT REPAIRED. THE VIN WAS UNAVAILABLE. THE FAILURE AND CURRENT MILEAGE WAS 101,000.
NHTSA ODI #10520096
70,500 miles · Jun 7, 2013
Engine
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED WHILE DRIVING APPROXIMATELY 60 MPH, THE VEHICLE STALLED AND THE CHECK ENGINE WARNING LIGHT ILLUMINATED. THE VEHICLE WAS TAKEN TO THE DEALER WHERE IT WAS DIAGNOSED THAT THE ENGINE AND SPARK PLUGS NEEDED TO BE REPLACED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. TH…
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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED WHILE DRIVING APPROXIMATELY 60 MPH, THE VEHICLE STALLED AND THE CHECK ENGINE WARNING LIGHT ILLUMINATED. THE VEHICLE WAS TAKEN TO THE DEALER WHERE IT WAS DIAGNOSED THAT THE ENGINE AND SPARK PLUGS NEEDED TO BE REPLACED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE VEHICLE WAS REPAIRED BUT THE FAILURE RECURRED. THE APPROXIMATE FAILURE MILEAGE WAS 70,500 AND THE CURRENT MILEAGE WAS 70,628. *TR
NHTSA ODI #10515622
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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