NHTSA owner reports · September 18, 2026 snapshot.
What owners actually said
299 reports81,200 miles · Apr 24, 2011
Engine And Engine CoolingFuel System, Gasoline
1/8/09 WHILE DRIVING AT 65 MPH ON HIGHWAY VEHICLE'S "ENGINE FAIL SAFE MODE" ALARM SOUNDED & MESSAGE FLASHED ON PANEL. VEHICLE IMMEDIATELY LOST POWER. I WAS ABLE TO COAST TO SHOULDER OF ROAD. TURNED OFF VEHICLE, RESTARTED AND WAS ABLE TO DRIVE APPROXIMATELY 1 1/2 MILES. I WAS IN TURN LANE, STARTED TO TURN LEFT, ALARM SOUNDED,…
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1/8/09 WHILE DRIVING AT 65 MPH ON HIGHWAY VEHICLE'S "ENGINE FAIL SAFE MODE" ALARM SOUNDED & MESSAGE FLASHED ON PANEL. VEHICLE IMMEDIATELY LOST POWER. I WAS ABLE TO COAST TO SHOULDER OF ROAD. TURNED OFF VEHICLE, RESTARTED AND WAS ABLE TO DRIVE APPROXIMATELY 1 1/2 MILES. I WAS IN TURN LANE, STARTED TO TURN LEFT, ALARM SOUNDED, MESSAGE FLASHED AND ALL POWER WAS GONE. I QUICKLY TURNED VEHICLE OFF AND BACK ON TO TRY AND GET OUT OF PATH OF ONCOMING TRACTOR TRAILER. I WAS ABLE TO GET JUST OFF ROADWAY AFTER 15 MINS STARTED VEHICLE, DROVE 4 MILES FAILED AGAIN. IT WAS TOWED TO MECHANIC. AFTER CALLS TO FORD AND FURTHER TESTING THE ELECTRONIC THROTTLE BODY ASSEMBLY WAS REPLACED. ON 1/30/10, 35 MILES FROM HOME, DRIVING ON HIGHWAY AT 55 MPH WHEN "ENGINE FAIL SAFE MODE" ALARM SOUNDED & MESSAGE FLASHED ON PANEL. AGAIN I WAS ABLE TO SAFELY PULL TO SHOULDER OF ROAD TO AVOID ACCIDENT. I CALLED FORD DEALER LOCATED IN THAT TOWN, HAD VEHICLE AGAIN TOWED TO SHOP AND THEY REPLACED AN ADDITIONAL PART. I CALLED FORD AFTER 2ND EVENT, I WAS TOLD BY FORD THAT THEY ARE AWARE OF THE PROBLEM, HOWEVER SINCE THEY DON'T HAVE A SOLUTION TO IT THEY DO NOT HAVE A RECALL ON THIS. ON 4/20/11 WHILE DRIVING HOME FROM WORK ON HIGHWAY AT 60 MPH THE "ENGINE FAIL SAFE MODE" ALARM & MESSAGE FLASHING ON PANEL. I WAS IN FAR RIGHT LANE SO AGAIN WAS ABLE TO COAST TO SHOULDER BEFORE STEERING LOCKED FROM NO POWER. IF I HAD BEEN IN LEFT LANE I WOULD NOT HAVE BEEN ABLE TO GET OFF ROADWAY. (ON 4/19/11 I HAD VEHICLE INSPECTED, IN NYS, NO CODES WERE ON THIS VEHICLE). TOWED TO SHOP, AFTER RUNNING TESTS AND CALLS TO FORD THEY HAVE AGAIN REPLACED THE ELECTRONIC THROTTLE BODY ASSEMBLY AS IT HAD FAILED. STILL NO RECALL. THIS IS EXTREME SAFETY ISSUE. I HAVE AVOIDED ACCIDENTS 3 TIMES, IF I HAD BEEN IN LEFT LANES I WOULD NOT HAVE BEEN SO LUCKY. THIS HAPPENS WITH NO ADVANCE WARNING. FORD KNOWS THERE IS A PROBLEM.
NHTSA ODI #10397771
82,000 miles · Apr 17, 2011
Electrical SystemEngine And Engine Cooling
I WAS DRIVING MY 2006 FORD EXPEDITION & THE FAIL SAFE ENGINE LIGHT CAME ON & THAT STOPS THE GAS PEDAL FROM WORKING. YOU THEN COAST OVER TO THE SIDE OF THE ROAD & TURN THE TRUCK OFF & RESTART IT LIKE NOTHING HAPPENED. THIS HAS HAPPENED 2 TIMES ABOUT 3 MONTHS APART. I HAD THE TRUCK CHECK BY BOB BOYD FORD & THEY SAID IT NEEDED THE …
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I WAS DRIVING MY 2006 FORD EXPEDITION & THE FAIL SAFE ENGINE LIGHT CAME ON & THAT STOPS THE GAS PEDAL FROM WORKING. YOU THEN COAST OVER TO THE SIDE OF THE ROAD & TURN THE TRUCK OFF & RESTART IT LIKE NOTHING HAPPENED. THIS HAS HAPPENED 2 TIMES ABOUT 3 MONTHS APART. I HAD THE TRUCK CHECK BY BOB BOYD FORD & THEY SAID IT NEEDED THE THROTTLE BODY & GAS PEDAL SENSOR REPLACED,I CALLED FORD & FILED A COMPLAINT OF HOW DANGEROUS THIS IS, ESPECIALLY IF YOU ARE MAKING A LEFT TURN IN ON COMING TRAFFIC( MY FORD CASE NUMBER [XXX]) I THEN WENT ON A FORD TRUCK FORUM & FOUND THAT MANY OTHERS HAD THE SAME PROBLEM WITH FORD F-150 & EXPEDITIONS ALL 2006 MODELS. A PERSON RECOMMENDED THAT I REPLACE THE THROTTLE POSITION SENSOR ,SO I DID AT BOB BOYD FORD FOR $196.58. I ALSO KEPT THE OLD PART.THE NEW PART IS DIFFERENT IN SIZE & HAS METAL KEY HOLES INSTEAD OF PLASTIC. THE FAIL SAFE ENGINE IS ONLY SUPPOSE TO COME ON IF THE ENGINE COOLANT IS VERY LOW ACCORDING TO THE FORD OWNERS MANUAL, THERE WAS NO REASON FOR IT TO COME ON AT ANY TIME IN MY SUV TRUCK. FORD WROTE ME & THE OHIO ATTORNEY GENERALS OFFICE & SAID THAT I HAVE FIXED THE PROBLEM BY REPLACING THE THROTTLE POSITION SENSOR ON MY OWN & ME PAYING FOR IT ( CASE CLOSED). FORD NEVER SAID ANY THING TO ME ABOUT REPLACING THE THROTTLE POSITION SENSOR TO FIX THIS PROBLEM. AGAIN THEY SAID IT WAS THE THROTTLE BODY & GAS PEDAL SENSOR. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR
NHTSA ODI #10396558
60,000 miles · Apr 6, 2011
Seat Belts
SEAT BELT BOLTS ON DRIVER AND PASSENGER SIDE SHOULDER MOUNTS WERE DISCOVERED TO BE NEARLY COMPLETELY LOOSENED, POTENTIALLY CAUSING INJURY OR DEATH IN EVENT OF AN ACCIDENT. BROUGHT IT TO THE ATTENTION OF THE DEALER, AND THEY CHARGED FOR THE TIGHTENING OF THE BOLTS. *TR
NHTSA ODI #10394497
76,000 miles · Apr 4, 2011
Engine And Engine CoolingPower Train
VEHICLE HAS BEEN SPUTTERING WHEN ACCELERATING AT ABOUT 40MPH. SPARK PLUGS ARE "SEERED" AND FORD MECHANIC TELLS US ITS A KNOWN PROBLEM, BUT NOT COVERED UNDER THE WARRANTY BECAUSE SPARK PLUGS ARE CONSIDERED MAINTENANCE. THE MANUAL SAYS WE THE SCHEDULED MAINTENANCE IS 100,000 MILES AND WE ARE ONLY AT 76,000. IF THEY ARE KNOWN TO B…
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VEHICLE HAS BEEN SPUTTERING WHEN ACCELERATING AT ABOUT 40MPH. SPARK PLUGS ARE "SEERED" AND FORD MECHANIC TELLS US ITS A KNOWN PROBLEM, BUT NOT COVERED UNDER THE WARRANTY BECAUSE SPARK PLUGS ARE CONSIDERED MAINTENANCE. THE MANUAL SAYS WE THE SCHEDULED MAINTENANCE IS 100,000 MILES AND WE ARE ONLY AT 76,000. IF THEY ARE KNOWN TO BE FAULTY AND WE ARE NOT NEAR THE SCHEDULED/RECOMMENDED MAINTEANCE THEN SHOULDN'T THIS BE A WARRANTY ISSUE? I THINK FORD IS MILKING ITS CUSTOMERS WITH FAULTY PARTS AS I HAD THE SAME ISSUE WITH MY BRAKES. IT FEELS AS IF I AM LANDING A PLANE WHEN I COME TO A STOP WITH ALL THE SHAKNIG AN RATTLING. I WAS TOLD THIS IS A KNOWN ISSUE WITH THE FORD BRAKES - THEY JUST WARP. *TR
NHTSA ODI #10394140
69,000 miles · Mar 28, 2011
Engine And Engine Cooling
THE VEHICLE ENTERS ENGINE FAIL SAFE MODE. AT THIS POINT, THE VEHICLE WILL SHUT OFF AND YOU WILL LOSE ENGINE POWER AND STEERING CAPABILITIES. THIS IS PARTICULARLY DANGEROUS WHEN DRIVING 70 MILES PER HOUR ON THE HIGHWAY. IT WILL EVENTUALLY KILL SOMEONE IF IT HAS NOT ALREADY. FORD HAS DROPPED THE BALL ON THIS ONE. THE REPAIR I…
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THE VEHICLE ENTERS ENGINE FAIL SAFE MODE. AT THIS POINT, THE VEHICLE WILL SHUT OFF AND YOU WILL LOSE ENGINE POWER AND STEERING CAPABILITIES. THIS IS PARTICULARLY DANGEROUS WHEN DRIVING 70 MILES PER HOUR ON THE HIGHWAY. IT WILL EVENTUALLY KILL SOMEONE IF IT HAS NOT ALREADY. FORD HAS DROPPED THE BALL ON THIS ONE. THE REPAIR IS A $600 - $800 THROTTLE BODY ASSEMBLY. FORD SHOULD BE EATING THIS COST.
NHTSA ODI #10393496
50,500 miles · Mar 25, 2011
Vehicle Speed Control
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT WAS DRIVING 30 MPH WHEN THE VEHICLE STALLED WITHOUT WARNING. THE FAILURE WOULD RECUR SPORADICALLY WHEN TRAVELING AT VARIOUS SPEEDS. THE VEHICLE WAS ABLE TO BE RESTARTED AND WAS TAKEN TO THE DEALER WHO REPAIRED THE THROTTLE BODY AND MOTOR ASSEMBLY, STATING THAT THE VEHICLE …
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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT WAS DRIVING 30 MPH WHEN THE VEHICLE STALLED WITHOUT WARNING. THE FAILURE WOULD RECUR SPORADICALLY WHEN TRAVELING AT VARIOUS SPEEDS. THE VEHICLE WAS ABLE TO BE RESTARTED AND WAS TAKEN TO THE DEALER WHO REPAIRED THE THROTTLE BODY AND MOTOR ASSEMBLY, STATING THAT THE VEHICLE HAD ENGAGED IN FAIL-SAFE MODE. THE MANUFACTURER WAS CONTACTED AND A COMPLAINT WAS FILED BUT NO FURTHER ASSISTANCE WAS PROVIDED. THE CURRENT MILEAGE WAS APPROXIMATELY 51,000 AND THE FAILURE MILEAGE WAS APPROXIMATELY 50,500.
NHTSA ODI #10392883
102,000 miles · Mar 18, 2011
Vehicle Speed Control
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. WHILE DRIVING APPROXIMATELY 50 MPH, THE CONTACT STATED THAT THE FAIL SAFE MODE SYMBOL ILLUMINATED ON THE DASHBOARD AS THE VEHICLE STALLED. THE VEHICLE WAS TAKEN TO THE DEALER BUT THEY WERE UNABLE TO DUPLICATE THE FAILURE. A PRIVATE MECHANIC DIAGNOSED THE VEHICLE WITH A THROTTLE BODY F…
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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. WHILE DRIVING APPROXIMATELY 50 MPH, THE CONTACT STATED THAT THE FAIL SAFE MODE SYMBOL ILLUMINATED ON THE DASHBOARD AS THE VEHICLE STALLED. THE VEHICLE WAS TAKEN TO THE DEALER BUT THEY WERE UNABLE TO DUPLICATE THE FAILURE. A PRIVATE MECHANIC DIAGNOSED THE VEHICLE WITH A THROTTLE BODY FAILURE. THE CONTACT DID NOT INFORM THE MANUFACTURER NOR WAS THE VEHICLE REPAIRED. THE CURRENT AND FAILURE MILEAGE WAS 102,000.
NHTSA ODI #10392175
Mileage unknown · Mar 10, 2011
Electrical SystemEngine And Engine Cooling
2006 FORD EXPEDITION. CONSUMER STATES VEHICLE WILL ACTIVATE THE ENGINE FAIL SAFE MODE AND VEHICLE WILL SHUT DOWN WHILE DRIVING *TGW THE CONSUMER STATED WHEN THE VEHICLE SHUT DOWN, LOSS OF POWER STEERING OCCURRED. THE CONSUMER STATED UPON STOPPING, HE DISCOVERED THAT TURNING THE IGNITION SWITCH TO THE OFF POSITION AND TURNING …
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2006 FORD EXPEDITION. CONSUMER STATES VEHICLE WILL ACTIVATE THE ENGINE FAIL SAFE MODE AND VEHICLE WILL SHUT DOWN WHILE DRIVING *TGW THE CONSUMER STATED WHEN THE VEHICLE SHUT DOWN, LOSS OF POWER STEERING OCCURRED. THE CONSUMER STATED UPON STOPPING, HE DISCOVERED THAT TURNING THE IGNITION SWITCH TO THE OFF POSITION AND TURNING IT BACK TO THE ON POSITION, THE ENGINE WOULD RE-START. THE DEALERSHIP WAS UNABLE TO FIND ANY PROBLEM BY RUNNING A DIAGNOSTIC CHECK. THE CONSUMER STATED NO WARNING LIGHTS APPEARED, EXCEPT WHEN THE ENGINE FAIL SAFE MODE ACTIVATED. THE ENGINE SAFE MODE WARNING DISAPPEARED UPON STARTING THE VEHICLE. *JB
NHTSA ODI #10389188
63,500 miles · Mar 1, 2011
Electrical System
2006 FORD EXPEDITION E.B. AND ENGINE FAILSAFE MODE 1. THE EVENTS LEADING UP TO THE FAILURE: THERE ARE NO DETECTABLE EVENTS PRECEDING WHATEVER CAUSES THE VEHICLE TO GO INTO "ENGINE FAILSAFE" MODE. THE VEHICLE RUNS FINE AS IT ALWAYS DOES AND THEN IT JUST HAPPENS RANDOMLY. 2. THE FAILURE, HOW OFTEN IT OCCURS, ITS CONSEQUENCES…
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2006 FORD EXPEDITION E.B. AND ENGINE FAILSAFE MODE 1. THE EVENTS LEADING UP TO THE FAILURE: THERE ARE NO DETECTABLE EVENTS PRECEDING WHATEVER CAUSES THE VEHICLE TO GO INTO "ENGINE FAILSAFE" MODE. THE VEHICLE RUNS FINE AS IT ALWAYS DOES AND THEN IT JUST HAPPENS RANDOMLY. 2. THE FAILURE, HOW OFTEN IT OCCURS, ITS CONSEQUENCES: FAILURE OCCURS AT RANDOM AND IS NOT PREDICTABLE IT JUST HAPPENS. THE VEHICLE OPERATES NORMALLY AS IT SHOULD AND IN A SPILT SECOND IT IS LIKE THE VEHICLE JUST SHUTS OFF, THE INFORMATION CENTER DISPLAYS "ENGINE IN FAILSAFE MODE". THE ENGINE IS ACTUALLY RUNNING IN FAILSAFE MODE BUT ONLY AT AN IDLE, THE POWER STEERING AND BRAKES FUNCTION HOWEVER THE THROTTLE IS TOTALLY UNRESPONSIVE IN FAILSAFE MODE, THE VEHICLE SLOWS TO A CREEP AND WILL STOP AT THE SLIGHTEST INCLINE. WHEN THE VEHICLE STOPS THE ONLY AVAILABLE OPTION IS TO TURN THE KEY OFF AND RESTART. THE VEHICLE ALWAYS RESTARTS AND RESUMES NORMAL OPERATION AND DRIVEABILTY IS FINE, JUST AS THOUGH NOTHING EVER HAPPENED. THE OCCURRENCE FIRST HAPPENED EARLY IN JANUARY 2010, AGAIN IN LATE JANUARY, THEN IN SEPTEMBER 2010 THEN AGAIN ON FEBRUARY 26 THEN TWICE TODAY FEBRUARY 28 ABOUT 20 MINUTES APART. THE CONSEQUENCES: SCARY, DANGEROUS, HAZARDOUS. FEELS LIKE AN INSURANCE CLAIM AND/OR A LAWSUIT WAITING TO HAPPEN. WHEN A VEHICLE UNDER POWER JUST SHUTS OFF INSTANTLY FOR NO APPARENT REASON IT IS LOGICAL SERIOUS INJURY OR WORSE IS A REALISTIC CONSEQUENCE. 3. WHAT WAS DONE TO CORRECT THE FAILURE: SO FAR JUST A LOT OF FORD GUESSWORK. THE INTERNET HAS A SIGNIFICANT NUMBER OF CONSUMER POSTS REGARDING VARIOUS REPAIRS MADE. THE REPORTED REPAIRS RANGE FROM SENSORS, SPARK PLUGS, COILS, CATS,FILTERS, CONVERTERS AND MORE. THE COMMON THREAD IN THESE CONSUMER REPORTS IS THE PROBLEM STILL EXISTS AND OCCURS RANDOMLY AFTER REPAIR. *TR
NHTSA ODI #10384861
75,000 miles · Feb 24, 2011
Engine And Engine Cooling
FOR THE FOURTH TIME IN THE PAST 2 YEARS THE SUV HAS SHUT DOWN WHILE DRIVING THE VEHICLE. THE DASHBOAD LIGHTS UP, THE STEERING WHEEL LOCKS UP, AND COMPLETELY SHUTS DOWN WHILE IN TRAFFIC. NO WARNING. HAVE TAKEN THE VEHICLE IN TWICE, BUT NO CODES HAVE SHOWN UP ON THE DIAGNOSTICS. THIS IS EXTREMELTY UNSAFE AND COULD RESULT IN A …
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FOR THE FOURTH TIME IN THE PAST 2 YEARS THE SUV HAS SHUT DOWN WHILE DRIVING THE VEHICLE. THE DASHBOAD LIGHTS UP, THE STEERING WHEEL LOCKS UP, AND COMPLETELY SHUTS DOWN WHILE IN TRAFFIC. NO WARNING. HAVE TAKEN THE VEHICLE IN TWICE, BUT NO CODES HAVE SHOWN UP ON THE DIAGNOSTICS. THIS IS EXTREMELTY UNSAFE AND COULD RESULT IN A AN ACCIDENT HARMING MY FAMILY, ANOTHER FAMILY OR BOTH. *TR
NHTSA ODI #10384296
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