NHTSA owner reports · September 18, 2026 snapshot.
What owners actually said
299 reports71,000 miles · Mar 11, 2013
Engine
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 25 MPH, THE ENGINE LOST POWER. THE CONTACT ALSO STATED THAT THE ACTIVATING FAIL SAFE MODE WARNING LIGHT ILLUMINATED. THE VEHICLE WAS TAKEN TO A MECHANIC FOR DIAGNOSIS. THE MECHANIC WAS UNABLE TO DIAGNOSE THE FAILURE. THE MANUFACTURER…
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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 25 MPH, THE ENGINE LOST POWER. THE CONTACT ALSO STATED THAT THE ACTIVATING FAIL SAFE MODE WARNING LIGHT ILLUMINATED. THE VEHICLE WAS TAKEN TO A MECHANIC FOR DIAGNOSIS. THE MECHANIC WAS UNABLE TO DIAGNOSE THE FAILURE. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE APPROXIMATE MILEAGE WAS 71,000.
NHTSA ODI #10502343
130,000 miles · Mar 6, 2013
Power Train
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING 40 MPH, THE TRANSMISSION SLIPPED. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC FOR INSPECTION AND THEY STATED THAT THE TRANSMISSION NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED. THE FAILURE MILEAGE WAS 130…
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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING 40 MPH, THE TRANSMISSION SLIPPED. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC FOR INSPECTION AND THEY STATED THAT THE TRANSMISSION NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED. THE FAILURE MILEAGE WAS 130,000. *TR
NHTSA ODI #10501850
58,318 miles · Feb 27, 2013
Electrical SystemEngine
ON 1/9/2013, I WAS DRIVING AT APPROX. 35 MPH WHEN THE ENGINE TURNED ITSELF OFF. I ATTEMPTED RESTARTING THE ENGINE TO NO AVAIL. I COASTED TO THE SIDE OF THE ROAD WHERE THE ENGINE STILL WOULD NOT START. AFTER WAITING ABOUT FIVE MINUTES, I WAS ABLE TO RESTART THE ENGINE. THE CAR SEEMED TO RUN SLOWLY ON THE WAY BACK HOME. …
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ON 1/9/2013, I WAS DRIVING AT APPROX. 35 MPH WHEN THE ENGINE TURNED ITSELF OFF. I ATTEMPTED RESTARTING THE ENGINE TO NO AVAIL. I COASTED TO THE SIDE OF THE ROAD WHERE THE ENGINE STILL WOULD NOT START. AFTER WAITING ABOUT FIVE MINUTES, I WAS ABLE TO RESTART THE ENGINE. THE CAR SEEMED TO RUN SLOWLY ON THE WAY BACK HOME. THE NEXT TIME I DROVE THE CAR, IT SEEMED TO RUN NORMALLY. ON 2/12/2013, MY WIFE WAS DRIVING THE CAR AT 25 MPH WHEN THE ENGINE DIED AGAIN. SHE HAD TO COAST TO THE SIDE OF THE ROAD & WAIT TO RESTART THE CAR. SHE SLOWLY DROVE BACK HOME WITH THE VEHICLE. NEXT TIME THE CAR WAS TAKEN OUT, IT RAN NORMALLY. I AM CONCERNED THAT THIS PROBLEM COULD OCCUR ON THE INTERSTATE HIGHWAYS AT A HIGHER SPEED & THE RESULT COULD HAVE BEEN VASTLY DIFFERENT. *TR
NHTSA ODI #10500639
119,000 miles · Feb 25, 2013
Engine
THIS IS THE 1ST COMPLAINT ON THIS ISSUE. WHILE DRIVING DOWN THE ROAD, THE ENGINE FAIL SAFE MODE ENGAGES, THE ENGINE LOSES POWER, FOR NO APPARENT REASON. YOU PULL OVER IF YOU CAN. PUT THE VEHICLE IN PARK. TURN EVERYTHING OFF. SHUT OFF ENGINE. RESTART AND IF YOU ARE LUCKY, PUT IT IN DRIVE AND CONTINUE ON. THIS IS VERY DANGEROUS, I…
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THIS IS THE 1ST COMPLAINT ON THIS ISSUE. WHILE DRIVING DOWN THE ROAD, THE ENGINE FAIL SAFE MODE ENGAGES, THE ENGINE LOSES POWER, FOR NO APPARENT REASON. YOU PULL OVER IF YOU CAN. PUT THE VEHICLE IN PARK. TURN EVERYTHING OFF. SHUT OFF ENGINE. RESTART AND IF YOU ARE LUCKY, PUT IT IN DRIVE AND CONTINUE ON. THIS IS VERY DANGEROUS, IF SOMEONE IS TAILGATING YOU AND THIS HAPPENS, THEY COULD REAR END YOUR VEHICLE AND PEOPLE COULD HAVE A MAJOR ACCIDENT AND DIE. THIS HAS HAPPENED 4 TIMES NOW. THERE'S ARE HUNDREDS OF COMPLAINTS ON THIS ISSUE ONLINE. THANK YOU. *TR
NHTSA ODI #10499913
Mileage unknown · Jan 18, 2013
Engine
ENGINE LOST THROTTLE CONTROL, REDUCED TO IDLE AND THEN STALLED. I COASTED OFF ROAD, AND RESTARTED AFTER 2 ATTEMPTS. *TR
NHTSA ODI #10493471
70,000 miles · Jan 2, 2013
Engine
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 20-60 MPH, THE SAFE MODE OPERATION ENGAGED AND CAUSED THE VEHICLE TO STALL. THE VEHICLE WAS TAKEN TO THE DEALER AND AN INDEPENDENT MECHANIC FOR DIAGNOSIS, AND NEITHER WAS ABLE TO DIAGNOSE THE FAILURE. THE VEHICLE WAS NOT REPAIRED. TH…
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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 20-60 MPH, THE SAFE MODE OPERATION ENGAGED AND CAUSED THE VEHICLE TO STALL. THE VEHICLE WAS TAKEN TO THE DEALER AND AN INDEPENDENT MECHANIC FOR DIAGNOSIS, AND NEITHER WAS ABLE TO DIAGNOSE THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS CONTACTED AND OFFERED NO ASSISTANCE. THE FAILURE MILEAGE WAS APPROXIMATELY 70,000. THE CURRENT MILEAGE WAS APPROXIMATELY 98,000. THE VIN WAS UNAVAILABLE. .. UPDATED 02-07-13 *BF UPDATED 02/13/2013 *JS
NHTSA ODI #10490748
85,000 miles · Dec 28, 2012
Vehicle Speed Control
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.
NHTSA ODI #10490327
106,500 miles · Dec 27, 2012
EngineService BrakesSteering
TWICE IN LAST WEEK, DRIVING AT SLOW SPEED AND "ENGINE FAIL SAFE MODE" LIGHT COMES ON. LOST POWER, BRAKING, AND STEERING. FORCED TO PUT CAR IN NEUTRAL WHILE CAR WAS ROLLING TO RESTART. ROLLED RIGHT THRU STOP SIGN. RESTARTED FINE, LUCKILY. IN SECOND EVENT, ALMOST GOT HIT WHEN TURNING LEFT ACROSS ONCOMING TRAFFIC! STARTED TUR…
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TWICE IN LAST WEEK, DRIVING AT SLOW SPEED AND "ENGINE FAIL SAFE MODE" LIGHT COMES ON. LOST POWER, BRAKING, AND STEERING. FORCED TO PUT CAR IN NEUTRAL WHILE CAR WAS ROLLING TO RESTART. ROLLED RIGHT THRU STOP SIGN. RESTARTED FINE, LUCKILY. IN SECOND EVENT, ALMOST GOT HIT WHEN TURNING LEFT ACROSS ONCOMING TRAFFIC! STARTED TURN AND COULDN'T STOP TURN DUE TO LOSS OF BRAKING. FORTUNATELY, FIRST TIME I TRIED THE RESTART IN NEUTRAL AND IT WORKED, OTHERWISE I WOULD HAVE BEEN HIT IN SECOND EVENT OR HIT SOMETHING SINCE I COULDN'T STEER. *TR
NHTSA ODI #10490170
140,000 miles · Dec 19, 2012
Engine
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT THE VEHICLE STALLED WHILE DRIVING 75 MPH. THE WARNING LIGHT STARTED TO ILLUMINATE AND SHOWED THAT THE ENGINE FAIL SAFE MODE HAD ENGAGED. THE VEHICLE WAS TAKEN TO THE DEALER WHO PREVIOUSLY RAN A DIAGNOSTIC TEST BUT COULD NOT FIND A FAILURE. THE CONTACT WAS ABLE …
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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT THE VEHICLE STALLED WHILE DRIVING 75 MPH. THE WARNING LIGHT STARTED TO ILLUMINATE AND SHOWED THAT THE ENGINE FAIL SAFE MODE HAD ENGAGED. THE VEHICLE WAS TAKEN TO THE DEALER WHO PREVIOUSLY RAN A DIAGNOSTIC TEST BUT COULD NOT FIND A FAILURE. THE CONTACT WAS ABLE TO SECURE AN APPOINTMENT TO HAVE THE DEALER FURTHER INSPECT THE VEHICLE. THE MANUFACTURER WAS NOTIFIED AND A COMPLAINT WAS FILED. THERE WERE NO RECALLS FOR THE FAILURE. THE FAILURE MILEAGE WAS 140,000.
NHTSA ODI #10489233
105,300 miles · Nov 5, 2012
Engine And Engine Cooling
I BOUGHT MY TRUCK USED FROM A DEALERSHIP IN JANUARY 2012. I HAD DRIVEN IT FOR ABOUT 8 WEEKS WHEN IT COMPLETELY DIED ON ME AT A STOP LIGHT BEFORE TAKE OFF. EVERYTHING WAS ON EXCEPT IT WOULD NOT GO AND THE MESSAGE CAME UP SAYING FAIL SAFE MODE. IT DID IT A COUPLE WEEKS LATER TAKING OFF FROM A STOP SIGN AND THEN AFTER THAT IT SEEME…
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I BOUGHT MY TRUCK USED FROM A DEALERSHIP IN JANUARY 2012. I HAD DRIVEN IT FOR ABOUT 8 WEEKS WHEN IT COMPLETELY DIED ON ME AT A STOP LIGHT BEFORE TAKE OFF. EVERYTHING WAS ON EXCEPT IT WOULD NOT GO AND THE MESSAGE CAME UP SAYING FAIL SAFE MODE. IT DID IT A COUPLE WEEKS LATER TAKING OFF FROM A STOP SIGN AND THEN AFTER THAT IT SEEMED TO DO IT ONCE A MONTH. THIS LAST TIME ON FRIDAY OCTOBER 26, 2012 IT DID IT WHILE I WAS PULLING OUT OF A STORE INTO THE MIDDLE OF TRAFFIC. I WAS LUCKY ENOUGH MY 3 YEAR OLD SON WAS NOT IN THE CAR TO WHERE IT WOULD HAVE HURT HIM AS WELL AS OTHERS AND MYSELF. I HAVE READ MANY ARTICLES AND COMPLAINTS FROM OTHER EXPEDITION OWNERS ABOUT THE EXPEDITIONS GOING INTO FAIL SAFE MODE IN THE MIDDLE OF TRAFFIC. IT IS VERY CONCERNING THAT THEY DO THIS AND THE DEALERSHIP HAS EVEN MADE COMMENTS ABOUT IT WHEN IT WAS EXAMINED. MY MOTHER WORKS FOR FORD AND SHE HAS SEEN MULTIPLE ISSUES WITH THIS. FORD NEEDS TO ISSUE A RECALL ON THESE HOWEVER THEY WILL NOT SEE ANYTHING WRONG UNLESS MULTIPLE PEOPLE ARE INJURED OR EVEN DEAD. IT IS FRUSTRATING TO KNOW I PAID OVER $20,000 ON A VEHICLE THAT I LOVE AND NEED BUT IS NOT SAFE FOR MYSELF AND MY FAMILY. I HAVE PRICED A THROTTLE BODY WITH MY MOTHER'S DISCOUNT AT WORK AND IT WAS ABOUT $210.00 AFTER TAX AND THE LABOR TO PUT IT IN IS AROUND $450.00. IF FORD WOULD FIX THIS PROBLEM PEOPLE WOULD NOT HAVE TO PAY SO MUCH JUST TO BE SAFE IN A VEHICLE THEY SPEND SO MUCH MONEY. PLEASE LOOK INTO ISSUING SOMETHING AGAINST THIS VEHICLE PROBLEM SO THAT OTHERS ARE SAFE. *TR
NHTSA ODI #10483436
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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