NHTSA owner reports · September 18, 2026 snapshot.
What owners actually said
299 reportsMileage unknown · Nov 1, 2012
Engine
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT THE VEHICLE WENT INTO SAFE MODE AT 65 MPH AND STALLED. THE FAILURE OCCURRED WITHOUT WARNING. THE CONTACT MENTIONED THAT THE FAILURE OCCURRED ON THREE DIFFERENT OCCASIONS AND THE CHECK ENGINE LIGHT ILLUMINATED IMMEDIATELLY AFTER THE FAILURE. THE VEHICLE WAS TAKE…
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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT THE VEHICLE WENT INTO SAFE MODE AT 65 MPH AND STALLED. THE FAILURE OCCURRED WITHOUT WARNING. THE CONTACT MENTIONED THAT THE FAILURE OCCURRED ON THREE DIFFERENT OCCASIONS AND THE CHECK ENGINE LIGHT ILLUMINATED IMMEDIATELLY AFTER THE FAILURE. THE VEHICLE WAS TAKEN TO THE DEALER AFTER THE FIRST FAILURE AND THE CATALYTIC CONVERTER WAS REPLACED. THE REMEDY FAILED TO REPAIR THE PROBLEM. THE VEHICLE WAS TAKEN TO A MECHANIC THE SECOND TIME WHO DIAGNOSED THAT THE CATALYTIC CONVERTER HAD FAILED AGAIN AND NEEDED TO BE REPLACED. THE FAILURE MILEAGE WAS UNKNOW AND THE CURRENT MILEAGE WAS 96,000.
NHTSA ODI #10482857
82,000 miles · Oct 11, 2012
Engine
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT THE CHECK ENGINE WARNING LIGHT ILLUMINATED ON THE DASHBOARD. IN ADDITION, THE VEHICLE WOULD STALL SPORADICALLY WHILE DRIVING 30 MPH. THE CONTACT TOOK THE VEHICLE TO A DEALER WHERE THE DEALER ADVISED THAT THE WIRING HARNESS NEEDED TO BE REPLACED. AFTER THE WIRI…
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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT THE CHECK ENGINE WARNING LIGHT ILLUMINATED ON THE DASHBOARD. IN ADDITION, THE VEHICLE WOULD STALL SPORADICALLY WHILE DRIVING 30 MPH. THE CONTACT TOOK THE VEHICLE TO A DEALER WHERE THE DEALER ADVISED THAT THE WIRING HARNESS NEEDED TO BE REPLACED. AFTER THE WIRING HARNESS WAS REPLACED, THE VEHICLE CONTINUED TO STALL SPORADICALLY. THE CONTACT TOOK THE VEHICLE BACK TO THE DEALER AND THE DEALER ADVISED THAT THE ENGINE NEEDED TO BE REPLACED. THE CONTACT HAD THE VEHICLE TOWED TO ANOTHER DEALER FOR A SECOND OPINION AND THE SECOND DEALER ADVISED THAT THE ENGINE NEEDED TO BE REPLACED. THE FAILURE MILEAGE WAS 82,000.
NHTSA ODI #10479803
90,000 miles · Oct 4, 2012
Air BagsEngineStructureCrashInjury
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
65,000 miles · Sep 30, 2012
Engine
MY 2006 FORD EXPEDITION HAS SHUT OFF MULTIPLE TIMES SINCE THE SUMMER OF 2010. IT WAS SERVICED IN THE SUMMER OF 2010 AND RAN FINE FOR A WHILE. IN 2011, IT STARTED CUTTING OFF AT RANDOM TIMES. I COULD BE AT A STOP LIGHT, INTERSECTION, DRIVING, OR TURNING THE CORNER. I HAVE HAD THE VEHICLE TESTED ABOUT 3 TIMES OVER THE LAST YEA…
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MY 2006 FORD EXPEDITION HAS SHUT OFF MULTIPLE TIMES SINCE THE SUMMER OF 2010. IT WAS SERVICED IN THE SUMMER OF 2010 AND RAN FINE FOR A WHILE. IN 2011, IT STARTED CUTTING OFF AT RANDOM TIMES. I COULD BE AT A STOP LIGHT, INTERSECTION, DRIVING, OR TURNING THE CORNER. I HAVE HAD THE VEHICLE TESTED ABOUT 3 TIMES OVER THE LAST YEAR AND NO ONE CAN SEEM TO FIGURE OUT THE PROBLEM. THE SCARIEST INCIDENT HAPPENED WHILE I WAS MAKING A LEFT TURN AT A BUSY INTERSECTION AND THE VEHICLE SHUT OFF AND THE POWER STEERING WENT OUT. I TURNED ON THE HAZARD LIGHT, PUT THE CAR IN PARK AND STARTED IT VERY QUICKLY. THE VEHICLE STARTED UP WITH NO PROBLEM. LUCKILY NO ONE WAS BEHIND ME OR COMING TOWARDS ME. THIS PROBLEM NEEDS TO BE FIXED. I HAVE READ MULTIPLE POST ABOUT THIS PROBLEM AND FORD HAS NOT RECALLED THE VEHICLE YET. PLEASE HELP! *TR
NHTSA ODI #10478010
109,000 miles · Sep 27, 2012
Engine
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT VEHICLE STALLED WITH THE ILLUMINATION OF THE CHECK ENGINE WARNING LIGHT. THE VEHICLE WAS TAKEN TO A REPAIR SHOP WHERE A DIAGNOSTIC WAS PERFORMED. THE CONTACT WAS ADVISED THAT CYLINDERS 5, 6 AND 8 HAD MISFIRED. THE CONTACT REPLACED THE THREE SPARK PLUGS HOWEVER,…
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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT VEHICLE STALLED WITH THE ILLUMINATION OF THE CHECK ENGINE WARNING LIGHT. THE VEHICLE WAS TAKEN TO A REPAIR SHOP WHERE A DIAGNOSTIC WAS PERFORMED. THE CONTACT WAS ADVISED THAT CYLINDERS 5, 6 AND 8 HAD MISFIRED. THE CONTACT REPLACED THE THREE SPARK PLUGS HOWEVER, TOW BECAME FRACTURED. ONLY ONE OF THE FRACTURED SPARK PLUGS WAS REPLACED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE WHO OFFERED TO ASSIST THE CONTACT WITH THE REPAIR. THE FAILURE MILEAGE WAS 109,000. THE CURRENT MILEAGE WAS 109,889. THE VIN WAS NOT AVAILABLE.
NHTSA ODI #10477285
113,000 miles · Sep 26, 2012
Vehicle Speed Control
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT WAS TRAVELING 55 MPH WHEN THE ENGINE FAIL SAFE MODE WARNING LIGHT ILLUMINATED, CAUSING THE VEHICLE TO LOOSE POWER. THE VEHICLE WAS TAKEN TO THE DEALER AND THE CONTACT WAS TOLD THAT THE THROTTLE BODY NEEDED TO BE REPLACED. THE VIN WAS NOT AVAILABLE. THE FAILURE AND THE CURR…
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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT WAS TRAVELING 55 MPH WHEN THE ENGINE FAIL SAFE MODE WARNING LIGHT ILLUMINATED, CAUSING THE VEHICLE TO LOOSE POWER. THE VEHICLE WAS TAKEN TO THE DEALER AND THE CONTACT WAS TOLD THAT THE THROTTLE BODY NEEDED TO BE REPLACED. THE VIN WAS NOT AVAILABLE. THE FAILURE AND THE CURRENT MILEAGES WERE 113,000.
NHTSA ODI #10477178
53,754 miles · Aug 28, 2012
Engine
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING 55 MPH THE VEHICLE STALLED. THE VEHICLE WAS TAKEN TO THE DEALER WHO WAS UNABLE TO DIAGNOSE THE FAILURE. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE WHO DID NOT OFFER ANY ASSISTANCE AND REFERRED HIM TO THE DEALER. THE FAILURE MILEAGE WAS 53,754.…
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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING 55 MPH THE VEHICLE STALLED. THE VEHICLE WAS TAKEN TO THE DEALER WHO WAS UNABLE TO DIAGNOSE THE FAILURE. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE WHO DID NOT OFFER ANY ASSISTANCE AND REFERRED HIM TO THE DEALER. THE FAILURE MILEAGE WAS 53,754.
NHTSA ODI #10472812
107,000 miles · Aug 8, 2012
Engine
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING 40 MPH, THE VEHICLE STALLED AND THE ENGINE ENGAGED IN FAIL SAFE MODE. THE VEHICLE WAS TOWED TO AN INDEPENDENT MECHANIC WHO DIAGNOSED THAT THE AIR CONTROL VALVE WAS DEFECTIVE AND NEEDED TO BE REPLACED. AFTER THE REPAIR, THE VEHICLE FAILED TO ACCELE…
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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING 40 MPH, THE VEHICLE STALLED AND THE ENGINE ENGAGED IN FAIL SAFE MODE. THE VEHICLE WAS TOWED TO AN INDEPENDENT MECHANIC WHO DIAGNOSED THAT THE AIR CONTROL VALVE WAS DEFECTIVE AND NEEDED TO BE REPLACED. AFTER THE REPAIR, THE VEHICLE FAILED TO ACCELERATE. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 107,000. THE VIN WAS NOT AVAILABLE.
NHTSA ODI #10469718
Mileage unknown · Jul 23, 2012
Electrical System
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT THE COMPRESSOR AND THE AIR CONDITIONING FAILED. THE CONTACT TOOK THE VEHICLE TO THE DEALER AND WAS TOLD THAT THE COMPRESSOR WAS LEAKING, CAUSING THE AIR CONDITIONER FROM FUNCTIONING PROPERLY. THE CURRENT MILEAGE WAS 59,174 AND THE FAILURE MILEAGE WAS UNAVAILABL…
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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT THE COMPRESSOR AND THE AIR CONDITIONING FAILED. THE CONTACT TOOK THE VEHICLE TO THE DEALER AND WAS TOLD THAT THE COMPRESSOR WAS LEAKING, CAUSING THE AIR CONDITIONER FROM FUNCTIONING PROPERLY. THE CURRENT MILEAGE WAS 59,174 AND THE FAILURE MILEAGE WAS UNAVAILABLE.
NHTSA ODI #10467077
98,000 miles · Jul 19, 2012
Engine And Engine CoolingFuel/propulsion System
3RD TIME PROBLEMS WITH SPARK PLUGS AND FUEL INJECTOR....WAS TOLD BY DEALER THAT THIS YEAR MODEL THE INJECTORS ARE BAD FOR STICKING....LEAVING THE OWNER TO PAY FOR REPAIR COST AND THE EXPENSE OF CHANGING FORDS FAULTY SPARK PLUGS. *TR
NHTSA ODI #10466586
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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