NHTSA owner reports · September 18, 2026 snapshot.
What owners actually said
299 reports45,000 miles · Jul 15, 2011
Engine And Engine Cooling
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT THE SPARK PLUGS WAS CAUSING DAMAGE TO THE ENGINE. THE DEALER ADVISED THE CONTACT TO HAVE THE SPARK PLUGS REMOVED AND REPLACED WITH A DIFFERENT MODEL SPARK PLUG. THE MANUFACTURER WAS AWARE OF THE FAILURE. NO REPAIRS WERE PERFORMED. THE CURRENT AND FAILURE MI…
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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT THE SPARK PLUGS WAS CAUSING DAMAGE TO THE ENGINE. THE DEALER ADVISED THE CONTACT TO HAVE THE SPARK PLUGS REMOVED AND REPLACED WITH A DIFFERENT MODEL SPARK PLUG. THE MANUFACTURER WAS AWARE OF THE FAILURE. NO REPAIRS WERE PERFORMED. THE CURRENT AND FAILURE MILEAGES WERE 45,000.
NHTSA ODI #10412447
104,000 miles · Jun 17, 2011
Engine And Engine Cooling
TL*THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT CARBON BUILT UP AROUND THE SPARK PLUGS AND HE WAS UNABLE TO REMOVE IT SINCE ONE OF THE SPARK PLUGS FRACTURED IN HALF AND THE OTHER PART WAS STUCK IN THE VEHICLE; HOWEVER, IF HE WERE TO REMOVE THEM IT WOULD CAUSE SERIOUS DAMAGE TO THE ENGINE. THE DEALER ADVISED T…
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TL*THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT CARBON BUILT UP AROUND THE SPARK PLUGS AND HE WAS UNABLE TO REMOVE IT SINCE ONE OF THE SPARK PLUGS FRACTURED IN HALF AND THE OTHER PART WAS STUCK IN THE VEHICLE; HOWEVER, IF HE WERE TO REMOVE THEM IT WOULD CAUSE SERIOUS DAMAGE TO THE ENGINE. THE DEALER ADVISED THE CONTACT TO BRING THE VEHICLE IN FOR SERVICE. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS AWARE OF THE FAILURE. THE CURRENT AND FAILURE MILEAGE WAS 104,000. THE VIN WAS UNAVAILABLE.
NHTSA ODI #10407257
100,532 miles · Jun 15, 2011
Air BagsCrash
2006 FORD EXPEDITION INVOLVED IN HEAD ON ACCIDENT AND AIRBAGS DID NOT DEPLOY. FORD EXPEDITION WAS DRIVING SOUTHBOUND ON A FOUR LANE DIVIDED STREET ABOUT 30-35 MPH WHEN A MINIVAN TRAVELING NORTHBOUND BLINDLY TRIED TO MAKE A LEFT TURN INTO A SHOPPING PLAZA AND TURNED RIGHT IN FRONT OF ME. AN RV WAS SITTING IN THE CENTER MEDIAN BLO…
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2006 FORD EXPEDITION INVOLVED IN HEAD ON ACCIDENT AND AIRBAGS DID NOT DEPLOY. FORD EXPEDITION WAS DRIVING SOUTHBOUND ON A FOUR LANE DIVIDED STREET ABOUT 30-35 MPH WHEN A MINIVAN TRAVELING NORTHBOUND BLINDLY TRIED TO MAKE A LEFT TURN INTO A SHOPPING PLAZA AND TURNED RIGHT IN FRONT OF ME. AN RV WAS SITTING IN THE CENTER MEDIAN BLOCKING HER VIEW. I HIT HER PASSENGER REAR SIDE HEAD ON. I HAD 3 CHILDREN IN THE CAR. NO AIRBAGS DEPLOYED. WHY THE HECK DO I EVEN HAVE THEM IF THEY AREN'T GOING TO WORK WHEN NEEDED? I AM CONCERNED ABOUT THE AIRBAGS NOT DEPLOYING. I DON'T FEEL SAFE IN MY EXPEDITION AND I AM AFRAID TO DRIVE IT AGAIN. I DON'T FEEL IT IS SAFE... ISN'T THE SAFETY EQUIPMENT SUPPOSED TO PROTECT US AND KEEP US SAFE AND WORK?? *TR
NHTSA ODI #10406971
Mileage unknown · Jun 10, 2011
Unknown Or Other
FALSE ACTIVATION OF "ENGINE FAILURE MODE" SYSTEM. ENGINE WENT TO IDLE SPEED, ALL GAUGES READ NORMALLY AND NO WARNING LIGHTS CAME ON. ENGINE TEMPERATURE WAS IN NORMAL RANGE. "ENGINE FAILURE MODE" MESSAGE WAS DISPLAYED ON MESSAGE PANEL. I WAS ABLE TO SAFELY COAST OFF THE ROAD AND STOP THE VEHICLE. I TURNED THE IGNITION OFF, AND OB…
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FALSE ACTIVATION OF "ENGINE FAILURE MODE" SYSTEM. ENGINE WENT TO IDLE SPEED, ALL GAUGES READ NORMALLY AND NO WARNING LIGHTS CAME ON. ENGINE TEMPERATURE WAS IN NORMAL RANGE. "ENGINE FAILURE MODE" MESSAGE WAS DISPLAYED ON MESSAGE PANEL. I WAS ABLE TO SAFELY COAST OFF THE ROAD AND STOP THE VEHICLE. I TURNED THE IGNITION OFF, AND OBSERVED THAT THE ENGINE COOLANT LEVEL IN THE COOLANT TANK WAS NORMAL. I THEN RESTARTED THE ENGINE, AND VEHICLE THEN OPERATED NORMALLY.
NHTSA ODI #10406490
80,000 miles · Jun 9, 2011
Engine And Engine Cooling
TL*THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED WHILE DRIVING 65 MPH THE VEHICLE STALLED WITHOUT ANY WARNING. THE VEHICLE WAS TAKEN TO THE DEALER WHO WAS UNABLE TO DUPLICATE THE FAILURE. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 80,000 AND THE CURREN…
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TL*THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED WHILE DRIVING 65 MPH THE VEHICLE STALLED WITHOUT ANY WARNING. THE VEHICLE WAS TAKEN TO THE DEALER WHO WAS UNABLE TO DUPLICATE THE FAILURE. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 80,000 AND THE CURRENT MILEAGE WAS 142,000.
NHTSA ODI #10405777
59,000 miles · Jun 8, 2011
Fuel System, Gasoline
I WAS COMING ACROSS ARIZONA, INTERSTATE 10 IN MY 2006 EXPEDITION HEADING HOME TO SAN DIEGO WHEN MY "ENGINE FAILSAFE MODE" INDICATOR CAME ON, THE ENGINE WARNING LIGHT WAS ON AND SHUT THE ENGINE DOWN. THE ENGINE WARNING LIGHT NEVER WENT OFF UNTIL I TOOK IT TO A MECHANIC THE FOLLOWING MORNING. THE MECHANIC STATED THAT I NEED TO HAV…
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I WAS COMING ACROSS ARIZONA, INTERSTATE 10 IN MY 2006 EXPEDITION HEADING HOME TO SAN DIEGO WHEN MY "ENGINE FAILSAFE MODE" INDICATOR CAME ON, THE ENGINE WARNING LIGHT WAS ON AND SHUT THE ENGINE DOWN. THE ENGINE WARNING LIGHT NEVER WENT OFF UNTIL I TOOK IT TO A MECHANIC THE FOLLOWING MORNING. THE MECHANIC STATED THAT I NEED TO HAVE THE THROTTLE CLEANED OUT AND MAY NEED A NEW SENSOR FOR THE SIDE OF THE THROTTLE REPLACED. I HAVE 59K MILES ON MY VEHICLE AND HAVE THE MAINT. COMPLETED EVERY 4K TO 6K AND HAVE OWNED THIS VEHICLE FROM THE START. I HAD 2 MILES ON THE VEHICLE WHEN WE PURCHASED THIS VEHICLE IN OCT 2005. AFTER READING ABOUT THIS PROBLEM WITH OTHER OWNERS I THINK FORD SHOULD BE ABLE TO REPAIR OR REPLACE THE PROBLEM WITHOUT CHARGING THE CUSTOMER. THIS IS THE SECOND TIME THIS HAS HAPPENED TO ME. BOTH TIMES WE HAD THE CRUISE CONTROL TURNED ON. AFTER STOPPING IN THE MIDDLE PART OF ARIZONA ON THE SIDE OF THE ROAD, WE RESTARTED THE MOTOR AND MADE IT BACK HOME AFTER OUR VACATION. *TR
NHTSA ODI #10405638
Mileage unknown · May 28, 2011
Air BagsCrash
WAS INVOLVED IN A (3) THREE VEHICLE ACCIDENT IN JANUARY 2011 ON STATE ROUTE 28 ON BLACK ICE CONDITIONS. VEHICLE #1 HIT BLACK ICE AND LOST CONTROL STRIKING MY 2006 FORD EXPEDITION SEVERAL TIMES AND THEN MY EXPEDITION WAS REAR-ENDED BY ANOTHER VEHICLE DURING THE COLLISION. I DID HAVE MY SEAT BELT ON AND LUCKILY WAS NOT SEVERELY …
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WAS INVOLVED IN A (3) THREE VEHICLE ACCIDENT IN JANUARY 2011 ON STATE ROUTE 28 ON BLACK ICE CONDITIONS. VEHICLE #1 HIT BLACK ICE AND LOST CONTROL STRIKING MY 2006 FORD EXPEDITION SEVERAL TIMES AND THEN MY EXPEDITION WAS REAR-ENDED BY ANOTHER VEHICLE DURING THE COLLISION. I DID HAVE MY SEAT BELT ON AND LUCKILY WAS NOT SEVERELY INJURED. NEITHER OF MY FRONT AIR-BAGS DEPLOYED AND MY EXPEDITION SUFFERED $14,000 DOLLARS IN FRONT END DAMAGE ALONE. THE AIRBAG SENSOR WAS DAMAGED AND SHOULD OF DEPLOYED THE AIR-BAGS BUT DID NOT. MY VEHICLE WAS REPAIRED BUT REPAIR SHOP AND STATE POLICE WERE BOTH SURPRISED AIR BAGS DID NOT DEPLOY. NOW I AM HAVING PROBLEMS WITH THE AIRBAG SENSOR AS IT LIGHTS UP ALL THE TIME AND NO PROBLEMS CAN BE FOUND WHEN DIAGNOSED. THIS IS A SERIOUS SAFETY CONCERN AND NEED TO BE ADDRESSED. I STILL OWN MY EXPEDITION AND WORRY FOR SAFETY IF ANOTHER COLLISION OCCURS WILL THE AIR-BAGS DEPLOY TO SAVE A LIFE. *TR
NHTSA ODI #10403653
85,000 miles · May 25, 2011
Engine And Engine Cooling
TL*THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THE COOLANT HOSE IN THE VEHICLE WAS LEAKING INTO THE VEHICLE. THE FAILURE CAUSED THE RADIATOR TO MALFUNCTION. THE CONTACT TOOK THE VEHICLE DEALER TO HAVE THE HOSE REPLACED, THE DEALER STATED THE HOSE WAS NO LONGER AVAILABLE. THE CONTACT STATED THE VEHICLE WOULD SHUT …
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TL*THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THE COOLANT HOSE IN THE VEHICLE WAS LEAKING INTO THE VEHICLE. THE FAILURE CAUSED THE RADIATOR TO MALFUNCTION. THE CONTACT TOOK THE VEHICLE DEALER TO HAVE THE HOSE REPLACED, THE DEALER STATED THE HOSE WAS NO LONGER AVAILABLE. THE CONTACT STATED THE VEHICLE WOULD SHUT OFF INTERMITTENTLY DUE TO THE FAULTY HOSE. THE FAILURE MILEAGE WAS 85,000.
NHTSA ODI #10402720
55,000 miles · May 10, 2011
Engine And Engine Cooling
THERE IS NO WARNING - MY FORD EXPEDITION JUST GOES INTO ENGINE FAIL SAFE MODE AND SHUTS OFF - NO ABILITY TO STEER, DRIVE ETC. WAS TRAVELING ON HIGHWAY AT HIGHWAY SPEEDS (55+ MPH) WHEN THIS HAPPENED. THE ENGINE FAIL SAFE HAD COME ON BEFORE BUT WAS A BIT SCARY UPON DRIVING AT A SPEED. THE DEALERSHIP STATES THAT THE THROTTLE BODY N…
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THERE IS NO WARNING - MY FORD EXPEDITION JUST GOES INTO ENGINE FAIL SAFE MODE AND SHUTS OFF - NO ABILITY TO STEER, DRIVE ETC. WAS TRAVELING ON HIGHWAY AT HIGHWAY SPEEDS (55+ MPH) WHEN THIS HAPPENED. THE ENGINE FAIL SAFE HAD COME ON BEFORE BUT WAS A BIT SCARY UPON DRIVING AT A SPEED. THE DEALERSHIP STATES THAT THE THROTTLE BODY NEEDS TO BE REPLACED. MY VEHICLE ONLY HAS 55000 MILES ON IT - AND FROM READING OTHER FORUMS I SEE THAT THIS IS A PROBLEM WITH A LOT OF FORD EXPEDITIONS. IT IS IN THE SHOP NOW (AT A COST OF $700) BEING FIXED, I AM GOING TO REQUEST TO HAVE THE OLD PARTS SAVED SO I CAN KEEP FOR FUTURE REFERENCE. I BELIEVE THIS IS A MAJOR DEFECT THAT NEEDS TO BE FIXED AS IT WILL CAUSE A DEATH ONE DAY SOON - AS THE VEHICLE SHUTS OFF DURING DRIVING. *TR
NHTSA ODI #10399803
125,000 miles · Apr 27, 2011
Fuel System, GasolineFire
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT WAS DRIVING APPROXIMATELY 55 MPH WHEN THE VEHICLE BEGAN TO DECELERATE INDEPENDENTLY. THE VEHICLE WAS MOVED FROM THE ROADWAY AND WHEN THE CONTAC EXITED, THERE WAS AN ABNORMAL BURNING ODOR AND BLACK SMOKE EMITTING FROM THE TAILPIPE. THE POLICE WERE DISPATCHED AND WHEN THEY A…
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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT WAS DRIVING APPROXIMATELY 55 MPH WHEN THE VEHICLE BEGAN TO DECELERATE INDEPENDENTLY. THE VEHICLE WAS MOVED FROM THE ROADWAY AND WHEN THE CONTAC EXITED, THERE WAS AN ABNORMAL BURNING ODOR AND BLACK SMOKE EMITTING FROM THE TAILPIPE. THE POLICE WERE DISPATCHED AND WHEN THEY ARRIVED AND OPENED THE REAR DRIVER SIDE DOOR, THICK BLACK SMOKE WAS POURING OUT FROM THE INSIDE OF THE VEHICLE. THERE WERE ALSO FLAMES FROM THE INTERIOR AND UNDER THE FRAME. THE FIRE WAS EXTINGUISHED BY THE LOCAL FIRE DEPARTMENT. THE FIRE CHIEF ADVISED THAT THERE WAS A HOLE IN THE FUEL LINE AND AN ELECTRICAL PROBLEM THAT COULD HAVE CAUSED THE FIRE BUT THE RESULTS WERE INCONCLUSIVE. THE VEHICLE WAS TOWED BY THE CONTACTS INSURANCE COMPANY. THE INSURANCE ADJUSTER INFORMED THE CONTACT THAT THE VEHICLE WAS DESTROYED AND THEY WERE UNABLE TO DETERMINE THE CAUSE OF THE FIRE. THERE WERE NO INJURIES. THE MANUFACTURER WAS NOT CONTACTED TO REPORT THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 125,000.
NHTSA ODI #10397988
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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