NHTSA owner reports · September 18, 2026 snapshot.
What owners actually said
299 reports95,000 miles · Jun 5, 2013
Engine
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING 70 MPH, THE FAIL SAFE WARNING LIGHT ILLUMINATED AS THE VEHICLE STALLED. THE VEHICLE WAS RESTARTED AND OPERATED AS DESIGNED. THE FAILURE RECURRED THREE TIMES. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE A…
Read full complaint
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING 70 MPH, THE FAIL SAFE WARNING LIGHT ILLUMINATED AS THE VEHICLE STALLED. THE VEHICLE WAS RESTARTED AND OPERATED AS DESIGNED. THE FAILURE RECURRED THREE TIMES. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE AND CURRENT MILEAGE WAS 95,000.
NHTSA ODI #10515349
59,851 miles · May 17, 2013
Service Brakes
I WENT TO MOVE MY VEHICLE FROM THE FRONT OF MY HOUSE TO THE DRIVE WAY AND IT WOULDN'T STOP, I PRESSED ON THE BRAKE PEDAL AND HEARD NOTHING BUT AIR AS THE BRAKE PEDAL WENT STRAIGHT TO THE FLOOR. I STEPPED ON THE EMERGENCY BRAKE TO STOP THE VEHICLE AND WHEN I GOT OUT.. THERE WAS A HUGE PUDDLE OF BRAKE FLUID BENEATH THE VEHICLE. …
Read full complaint
I WENT TO MOVE MY VEHICLE FROM THE FRONT OF MY HOUSE TO THE DRIVE WAY AND IT WOULDN'T STOP, I PRESSED ON THE BRAKE PEDAL AND HEARD NOTHING BUT AIR AS THE BRAKE PEDAL WENT STRAIGHT TO THE FLOOR. I STEPPED ON THE EMERGENCY BRAKE TO STOP THE VEHICLE AND WHEN I GOT OUT.. THERE WAS A HUGE PUDDLE OF BRAKE FLUID BENEATH THE VEHICLE. *TR
NHTSA ODI #10512575
85,000 miles · Apr 24, 2013
Engine
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING 60 MPH, THE ENGINE LIGHT ILLUMINATED AND THE STEERING BECAME DIFFICULT. THE VEHICLE WAS TAKEN TO A DEALER FOR DIAGNOSIS AND THE CONTACT WAS INFORMED THAT FIVE OF HER SPARK PLUGS HAD FRACTURED INSIDE THE CYLINDER. THE VEHICLE WAS REPAIRED. THREE MO…
Read full complaint
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING 60 MPH, THE ENGINE LIGHT ILLUMINATED AND THE STEERING BECAME DIFFICULT. THE VEHICLE WAS TAKEN TO A DEALER FOR DIAGNOSIS AND THE CONTACT WAS INFORMED THAT FIVE OF HER SPARK PLUGS HAD FRACTURED INSIDE THE CYLINDER. THE VEHICLE WAS REPAIRED. THREE MONTHS AFTER THE REPAIR, THE ENGINE LIGHT ILLUMINATED AND THE VEHICLE WAS RETURNED TO THE DEALER WHO STATED THAT THE SPARK PLUG FAILURE HAD CAUSED THE CATALYTIC CONVERTER TO FAIL AND IT WOULD NEED TO BE REPLACED. THE VEHICLE HAD NOT BEEN REPAIRED. THE FAILURE AND CURRENT MILEAGE WAS 85,000.
NHTSA ODI #10509385
103,000 miles · Apr 24, 2013
Engine
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED WHILE DRIVING 65 MPH, THE ENGINE FAIL SAFE MODE LIGHT ILLUMINATED AND THE VEHICLE STOPPED ACCELERATING. THE VEHICLE WAS RESTARTED AND OPERATED AS DESIGNED. IT WAS THE SECOND TIME THE FAILURE HAD OCCURRED. THE MANUFACTURER WAS NOTIFIED AND ADVISED THE CONTACT TO TAKE…
Read full complaint
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED WHILE DRIVING 65 MPH, THE ENGINE FAIL SAFE MODE LIGHT ILLUMINATED AND THE VEHICLE STOPPED ACCELERATING. THE VEHICLE WAS RESTARTED AND OPERATED AS DESIGNED. IT WAS THE SECOND TIME THE FAILURE HAD OCCURRED. THE MANUFACTURER WAS NOTIFIED AND ADVISED THE CONTACT TO TAKE THE VEHICLE TO A DEALER FOR DIAGNOSIS. THE VEHICLE HAD NOT BEEN REPAIRED. THE FAILURE AND CURRENT MILEAGE WAS 103,000.
NHTSA ODI #10509382
78,468 miles · Apr 12, 2013
Power Train
DRIVING 30MPH IN (D) WITH O/D ON AND LOST FORWARD MOMENTUM JUST LIKE I PUT IT IN NEUTRAL. HAD TO DRIVE IN L2 TO GET HOME.THIS WAS THE FIRST AND ONLY TIME THIS HAPPENED. TOOK A TEST DRIVE AFTER I CHECKED FLUID LEVELS THAT WERE FULL AND PROPER WHICH I WISHED WERE LOW(EASY FIX).I TOOK IT DOWN THE ROAD IN D BUT SLIPPED OUT ABOUT 50'…
Read full complaint
DRIVING 30MPH IN (D) WITH O/D ON AND LOST FORWARD MOMENTUM JUST LIKE I PUT IT IN NEUTRAL. HAD TO DRIVE IN L2 TO GET HOME.THIS WAS THE FIRST AND ONLY TIME THIS HAPPENED. TOOK A TEST DRIVE AFTER I CHECKED FLUID LEVELS THAT WERE FULL AND PROPER WHICH I WISHED WERE LOW(EASY FIX).I TOOK IT DOWN THE ROAD IN D BUT SLIPPED OUT ABOUT 50' LATER BUT I TOOK IT OUT OF O/D OVERDRIVE AND WENT DOWN THE ROAD FINE FOR 2 MILES BUT DIDN'T WANT TO DRIVE IT ANYMORE UNTIL I TOOK IT TO THE TRANSMISSION GARAGE. WE TREAT OUR VEHICLES EXCELLENT AND I HAVE NEVER HAULED ANYTHING BUT FAMILY AROUND,NO TRAILERS,NO PLOWS..NO PULLING OF ANY KIND.THERE WERE NO PRIOR INDICATORS EXCEPT A SMALL WHINE THAT GOT A LITTLE LOUDER WHEN I ACCELERATED BUT ONLY HEARD IT MAYBE 10 TIMES AT MOST BUT DON'T KNOW IF THAT MEANS ANYTHING WITH THE TRANSMISSION...PLEASE HELP WERE NOT RICH$$ *TR
NHTSA ODI #10506064
98,000 miles · Apr 9, 2013
Engine
ENGINE SHUTS OFF WHILE DRIVING AND SHOWS 'ENGINE FAIL SAFE MODE'. THIS HAS HAPPENED 6 TIMES SINCE I BOUGHT THE VEHICLE IN MARCH 2012 (I'VE HAD THE VEHICLE A LITTLE OVER A YEAR NOW). IT HAS HAPPENED IN 1) A RESTAURANT PARKING LOT WHILE ON VACATION; 2) IN A PARKING GARAGE AT WORK; 3) IN A STORE PARKING LOT; 4) IN A STORE PARKING L…
Read full complaint
ENGINE SHUTS OFF WHILE DRIVING AND SHOWS 'ENGINE FAIL SAFE MODE'. THIS HAS HAPPENED 6 TIMES SINCE I BOUGHT THE VEHICLE IN MARCH 2012 (I'VE HAD THE VEHICLE A LITTLE OVER A YEAR NOW). IT HAS HAPPENED IN 1) A RESTAURANT PARKING LOT WHILE ON VACATION; 2) IN A PARKING GARAGE AT WORK; 3) IN A STORE PARKING LOT; 4) IN A STORE PARKING LOT; 5) ON A ROAD; 6) IN A STORE PARKING LOT. (#5/#6 JUST HAPPENED YESTERDAY TO MY WIFE WHILE SHOPPING WITH OUR 3YR. OLD SON). THIS IS A SERIOUS SAFETY ISSUE BECAUSE IT CAN HAPPEN ANY TIME, ANYWHERE, WITHOUT WARNING. I HAVE CONTACTED FORD AND OF COURSE THEY SAY THEY ARE NOT AWARE OF THE PROBLEM - EVEN THOUGH I HAVE FOUND HUNDREDS OF COMPLAINTS ON VARIOUS ONLINE FORUMS AND RIGHT HERE ON THE NHTSA WEBSITE. IT SEEMS (FROM MY RESEARCH ONLINE) THAT THE PROBLEM CAN BE FIXED BY REPLACING THE THROTTLE BODY AND TPS - WHICH IS A COSTLY REPAIR FOR WHICH I DO NOT HAVE THE MONEY (AFTER JUST BUYING NEW TIRES IN ADDITION TO A SEPARATE $500 REPAIR). FORD NEEDS TO RECALL AND FIX THIS ISSUE BEFORE SOMEONE IS INJURED OR KILLED!! *TR
NHTSA ODI #10505626
62,000 miles · Apr 4, 2013
Vehicle Speed Control
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 …
Read full complaint
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.
NHTSA ODI #10507117
70,000 miles · Mar 27, 2013
Engine
WHILE TRAVELING ON THE HIGHWAY AT APPROXIMATELY 75 MPH IN A 2006 FORD EXPEDITION, THE VEHICLE'S ENGINE SUDDENLY AND WITHOUT WARNING SHUT DOWN. DUE TO THE LOSS OF POWER, THE STEERING AND BRAKES WERE EXTREMELY DIFFICULT TO CONTROL. THE VEHICLE COASTED ON THE HIGHWAY UNTIL I WAS SAFELY ABLE TO DIRECT THE VEHICLE TO THE SIDE OF THE…
Read full complaint
WHILE TRAVELING ON THE HIGHWAY AT APPROXIMATELY 75 MPH IN A 2006 FORD EXPEDITION, THE VEHICLE'S ENGINE SUDDENLY AND WITHOUT WARNING SHUT DOWN. DUE TO THE LOSS OF POWER, THE STEERING AND BRAKES WERE EXTREMELY DIFFICULT TO CONTROL. THE VEHICLE COASTED ON THE HIGHWAY UNTIL I WAS SAFELY ABLE TO DIRECT THE VEHICLE TO THE SIDE OF THE ROADWAY. AFTER STOPPING AND PARKING THE VEHICLE SAFELY, I WAS ABLE TO RESTART THE VEHICLE WITHOUT FURTHER INCIDENT. THIS OCCURED A TOTAL OF THREE TIMES IN MONTHS THAT FOLLOWED. I TOOK THE VEHICLE TO A FORD DEALERSHIP AND THEY COULD NOT FIND A PROBLEM WITH THE VEHICLE. AFTER RESEARCHING THE INCIDENT ONLINE, I LEARNED THAT THE THROTTLE CONTROL SWITCH MAY HAVE BEEN THE CAUSE OF THE PROBLEM. I NOTIFIED THE DEALERSHIP OF MY RESEARCH AND THEY DID NOT AGREE. I REPLACED THE SWITCH ON MY OWN AND I HAVE NOT ENCOUNTERED ANY ADDITIONAL ENGINE FAILURES SINCE. *TR
NHTSA ODI #10504652
49,000 miles · Mar 22, 2013
Vehicle Speed ControlCrash
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…
Read full complaint
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
NHTSA ODI #10504098
33,000 miles · Mar 20, 2013
Engine
RELATING TO ARTICLE HTTP://EDITORIAL.AUTOS.MSN.COM/BLOGS/AUTOSBLOGPOST-ROS.ASPX?POST=9D5D443C-A8B6-43A1-8CC6-5942B4C36E39&ICID=AUTOS_4051 MY VEHICLE HAS EXPERIENCED THE SAME ISSUE DOZENS OF TIME. I TOOK THE VEHICLE TO A DEALERSHIP, GUS MACHADO FORD IN MIAMI, FL AND MENTIONED THIS ISSUE. I WAS TOLD THEY WERE NOT AWARE OF THE P…
Read full complaint
RELATING TO ARTICLE HTTP://EDITORIAL.AUTOS.MSN.COM/BLOGS/AUTOSBLOGPOST-ROS.ASPX?POST=9D5D443C-A8B6-43A1-8CC6-5942B4C36E39&ICID=AUTOS_4051 MY VEHICLE HAS EXPERIENCED THE SAME ISSUE DOZENS OF TIME. I TOOK THE VEHICLE TO A DEALERSHIP, GUS MACHADO FORD IN MIAMI, FL AND MENTIONED THIS ISSUE. I WAS TOLD THEY WERE NOT AWARE OF THE PROBLEM WITH THE CAR GOING INTO ENGINE FAILSAFE MODE AND LOOSING POWER WHILE THE VEHICLE WAS STILL RUNNING. THE VEHICLE WAS UNDER FACTORY WARRANTY AT THAT POINT AND THEY REFUSED TO FIX IT. AT THAT TIME, I WAS NOT REALLY AWARE OF THE PROBLEM. AFTER IT HAPPENED AGAIN AND AGAIN, I DID SOME RESEARCH ONLINE AND FOUND OUT THAT THOUSANDS OF OWNERS ARE HAVING THE SAME PROBLEM. AT THE TIME THE VEHICLE WAS OUT OF FACTORY WARRANTY. I CONTACTED FORD A COUPLE OF YEAR AGO AND AGAIN THEY TOLD ME THEY WERE NOT AWARE OF THE PROBLEM, EVEN IF THEY ARE HUNDREDS AND HUNDREDS OF OWNERS THAT HAVE REPORTED THIS PROBLEM TO FORD AS DESCRIBED IN DIFFERENT BLOGS ONLINE. WHEN THIS HAPPENS, I HAVE TO FIND A PLACE TO STOP SINCE THE VEHICLE DOES NOT RESPOND TO THE GAS PEDAL EVEN IF IT IS STILL RUNNING. THE VEHICLE MUST BE TURNED OFF AND STARTED AGAIN. THIS IS A HUGE SAFETY CONCERN FOR ME A MY FAMILY, EVEN MORE NOW WITH A NEWBORN. IF IT HAPPENS WHILE ON THE EXPRESSWAY OR HIGHWAY, WE CAN BE REAR ENDED BY ANOTHER DRIVE OR TRUCK SINCE THE VEHICLE LOOSES POWER AND THE VEHICLE MUST BE TURNED OFF. HERE IN MIAMI, THERE IS A LOT OF CONSTRUCTION GOING ON AND HIGHWAYS ARE BEING EXPANDED. MUST OF THE CONSTRUCTION HAS ELIMINATED THE EMERGENCY LANE, WHICH MEANS THAT IF THAT HAPPENS, WE ARE GOING TO BE STRANDED IN THE MIDDLE OF THE HIGHWAY. I CONTACTED FORD AGAIN A FEW WEEKS AGO AND MENTIONED THE PROBLEM AGAIN, THEY STILL ""DON'T KNOW"" ABOUT THIS EVEN IF IT IS BEING INVESTIGATED BY THE NHTSA. PLEASE HELP. MY VEHICLE IS A FORD EXPEDITION 2006. *TR
NHTSA ODI #10503750
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