Illustration2006 FORD EXPEDITION FAILSAFE MODE COMES ON. IT HAS HAPPENED 4 TIMES IN 4 MONTHS. HAVE LOSS OF STEERING AND ENGINE HAS NO POWER. VERY DANGEROUS. *TR
2006 Ford Expedition
Owner reports · Recalls · Investigations
Similar to other model years
Owner complaints for the 2006 Ford Expedition do not stand out strongly from the model-year median of 155.
About this comparison →How this year compares
Owner complaints by model year
Compare all Expedition years →Counts vary with age, sales and reporting. They are not failure rates.
What owners reported most
All reported categories
Tap a category to read its complaints. One report may name several components.
When problems were reported
Mileage at the reported incident
220–25K
3425–50K
5750–75K
6875–100K
63100–150K
19150K+
263 reports with mileage · 36 unknown
NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.
What to inspect
Issues worth paying extra attention to based on owner reports.
- Engine. Review the 87 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Engine And Engine Cooling. Review the 75 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Electrical System. Review the 32 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
NHTSA owner reports · September 18, 2026 snapshot.
19 crash reports6 fire reports18 injury reports
What owners actually said
299 reportsTL* THE CONTACT OWNS A 2006 FORD EXPEDITION. WHILE DRIVING IN A PARKING LOT AT ABOUT 15MPH, THE VEHICLE JUST SHUT OFF. A LIGHT ON THE INSTRUMENT PANEL INDICATED THAT THE VEHICLE WAS IN " ENGINE FAIL SAFE MODE". THE CONTACT PUT HER HAZARD LIGHTS ON, PUT THE VEHICLE IN PARK AND TURNED THE ENGINE OFF. SHE RESTARTED THE VEHICLE A…
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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. WHILE DRIVING IN A PARKING LOT AT ABOUT 15MPH, THE VEHICLE JUST SHUT OFF. A LIGHT ON THE INSTRUMENT PANEL INDICATED THAT THE VEHICLE WAS IN " ENGINE FAIL SAFE MODE". THE CONTACT PUT HER HAZARD LIGHTS ON, PUT THE VEHICLE IN PARK AND TURNED THE ENGINE OFF. SHE RESTARTED THE VEHICLE AND IT OPERATED NORMALLY. THE CONTACT STATED THAT THIS HAS HAPPENED ABOUT 6-7 TIMES. SHE REPORTED THE FAILURE TO THE MANUFACTURER AND THEY STATED THAT THEY NEVER HEARD OF ANYTHING LIKE THIS. THE DRIVER DOES NOT FEEL HER VEHICLE IS SAFE. THE FAILURE MILEAGE WAS 40,000 AND THE CURRENT MILEAGE IS 52,691.
SPARKS PLUGS BLEW OUT RIGHT AT 60,000 MILES ON 2006 FORD EXPEDITION ON OUR WAY FROM MARYLAND TO LOUISIANA. STARTED GETTING PROBLEMS IN NORTH CAROLINA. AFTER SPENDING 2000.00 FOR HOTEL, RENTAL CAR AND POSSIBLE FIX BY FIRESTONE..IT STILL WAS NOT WORKING. BROUGHT TO FORD DEALERSHIP AND SAID IT WAS SPARK PLUGS THAT BLEW AND A COM…
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SPARKS PLUGS BLEW OUT RIGHT AT 60,000 MILES ON 2006 FORD EXPEDITION ON OUR WAY FROM MARYLAND TO LOUISIANA. STARTED GETTING PROBLEMS IN NORTH CAROLINA. AFTER SPENDING 2000.00 FOR HOTEL, RENTAL CAR AND POSSIBLE FIX BY FIRESTONE..IT STILL WAS NOT WORKING. BROUGHT TO FORD DEALERSHIP AND SAID IT WAS SPARK PLUGS THAT BLEW AND A COMMON THING FOR F150S AND IT WOULD COST OVER 7,000.00 TO FIX IT AND RECOMMENDED TRADING IT IN. SO WE DID CAUSE WE HAD NO CHOICE WITH THE TRUCK BEING IN NC. *TR
TL*THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT THE FAIL SAFE MODE WAS ACTIVATED AND MADE IT IMPOSSIBLE TO CONTINUE DRIVING AFTER THE VEHICLE WAS STOPPED. THE VEHICLE WOULD NOT ACCELERATE OR TURN IN ANY DIRECTION. IF THE VEHICLE WAS TURNED OFF AND RESTARTED THE VEHICLE WOULD FUNCTION PROPERLY. THE VEHICLE MAL…
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TL*THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT THE FAIL SAFE MODE WAS ACTIVATED AND MADE IT IMPOSSIBLE TO CONTINUE DRIVING AFTER THE VEHICLE WAS STOPPED. THE VEHICLE WOULD NOT ACCELERATE OR TURN IN ANY DIRECTION. IF THE VEHICLE WAS TURNED OFF AND RESTARTED THE VEHICLE WOULD FUNCTION PROPERLY. THE VEHICLE MALFUNCTIONED WHENEVER THE VEHICLE WAS PULLING OFF FROM A STOP. THE VEHICLE HAD 38,000 AT THE TIME OF THE FAILURE AND THE CURRENT MILEAGE WAS 38,500 CURRENT MILES.
REAR DOOR PAINT BLISTERS. *TR
ENGINE SHUTS OFF WHILE RUNNING. LAST TIME ON THE FREEWAY. MY MECHANIC SAYS THE SYSTEMS READS OK ON COMPUTER DIAGNOSTIC, BUT THE FAIL-SAFE SYSTEM DEFINITELY SHUT THE ENGINE DOWN DUE TO A POSSIBLE GLITCH IN THE SYSTEM. DEALERS "SEE" GOOD READINGS FOR THROTTLE SYSTEM AND WILL NOT REPLACE A "GOOD" PART. WHEN THIS HAPPENS, CAR HAS NO…
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ENGINE SHUTS OFF WHILE RUNNING. LAST TIME ON THE FREEWAY. MY MECHANIC SAYS THE SYSTEMS READS OK ON COMPUTER DIAGNOSTIC, BUT THE FAIL-SAFE SYSTEM DEFINITELY SHUT THE ENGINE DOWN DUE TO A POSSIBLE GLITCH IN THE SYSTEM. DEALERS "SEE" GOOD READINGS FOR THROTTLE SYSTEM AND WILL NOT REPLACE A "GOOD" PART. WHEN THIS HAPPENS, CAR HAS NO POWER WITH NO WARNING. IT HAS HAPPENED TWICE AND WE DON'T KNOW WHEN IT WILL HAPPEN AGAIN. *TR
TIRE RIM FAILURE ON A 2006 FORD EXPEDITION USED BY A U.S. FOREST SERVICE LAW ENFORCEMENT OFFICER. THE VEHICLE CURRENTLY HAS 88,607 MILES. AFTER REPORT 10307412, WE COMPLETED A FLEET WIDE INSPECTION OF FORD VEHICLES WITH STEEL WHEELS. THIS IS THE 4TH INCIDENT OF THIS NATURE TO OCCUR WITHIN 2 YEARS. THE OTHER 3 TIMES THE FAILURE O…
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TIRE RIM FAILURE ON A 2006 FORD EXPEDITION USED BY A U.S. FOREST SERVICE LAW ENFORCEMENT OFFICER. THE VEHICLE CURRENTLY HAS 88,607 MILES. AFTER REPORT 10307412, WE COMPLETED A FLEET WIDE INSPECTION OF FORD VEHICLES WITH STEEL WHEELS. THIS IS THE 4TH INCIDENT OF THIS NATURE TO OCCUR WITHIN 2 YEARS. THE OTHER 3 TIMES THE FAILURE OCCURRED ON OTHER FORD EXPEDITIONS. REPORTS WERE FILED HERE. SEE COMPLAINT 10286279, 10307412. BASED ON PRIOR 3 FAILURES, A UNIT-08 FOREST WIDE INSPECTION OF FORD VEHICLES WITH STEEL WHEELS IS UNDERWAY. I CURRENTLY HAVE TWO RIMS WITH TYPICAL RIM FAILURE AT THE BEAD FACE WELD FROM TWO DIFFERENT VEHICLES. PLEASE ADVISE IF PHOTO DOCUMENTATION IS REQUIRED. AFTER INSPECTION BY FORD TECHNICIAN, ALL 4 WHEELS WERE REPLACED. RECOMMEND FORD INITIATE A RECALL ON STEEL WHEEL FOR CRACK INSPECTION ASSOCIATED WITH 2003 AND NEWER FORD VEHICLES WITH STEEL WHEELS. *TR
TIRE RIM FAILURE ON A 2006 FORD EXPEDITION USED BY A U.S. FOREST SERVICE LAW ENFORCEMENT OFFICER. THE VEHICLE CURRENTLY HAS 71,000 MILES, THIS IS THE 3RD INCIDENT OF THIS NATURE TO OCCUR WITH 2 YEARS. THE OTHER 2 TIMES THE FAILURE OCCURRED ON ANOTHER FORD EXPEDITION. UNKNOWN IF REPORTS WERE FILED HERE. SEE COMPLAINT 10286279. …
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TIRE RIM FAILURE ON A 2006 FORD EXPEDITION USED BY A U.S. FOREST SERVICE LAW ENFORCEMENT OFFICER. THE VEHICLE CURRENTLY HAS 71,000 MILES, THIS IS THE 3RD INCIDENT OF THIS NATURE TO OCCUR WITH 2 YEARS. THE OTHER 2 TIMES THE FAILURE OCCURRED ON ANOTHER FORD EXPEDITION. UNKNOWN IF REPORTS WERE FILED HERE. SEE COMPLAINT 10286279. BASED ON PRIOR 2 FAILURES, A REGION WIDE INSPECTION OF FORD VEHICLES WITH STEEL WHEELS IS UNDERWAY. IF A PHOTO IS NEEDED, I HAVE THAT AS WELL
TL*THE CONTACT OWNS A 2006 FORD EXPEDITION WHICH WAS PURCHASED BRAND NEW. WHILE STEPPING ON THE ACCELERATOR PEDAL AT ANY SPEED INCLUDING APPROXIMATELY 25 MPH, THE PEDAL BECAME STUCK IN THE OPEN THROTTLE POSITION. THE VEHICLE WAS TAKEN TO THE DEALER; HOWEVER, THE FAILURE COULD NOT BE DUPLICATED. THE FAILURE WAS ALSO REPORTED TO …
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TL*THE CONTACT OWNS A 2006 FORD EXPEDITION WHICH WAS PURCHASED BRAND NEW. WHILE STEPPING ON THE ACCELERATOR PEDAL AT ANY SPEED INCLUDING APPROXIMATELY 25 MPH, THE PEDAL BECAME STUCK IN THE OPEN THROTTLE POSITION. THE VEHICLE WAS TAKEN TO THE DEALER; HOWEVER, THE FAILURE COULD NOT BE DUPLICATED. THE FAILURE WAS ALSO REPORTED TO THE MANUFACTURER. THERE WERE NO RECALLS. NO REPAIRS WERE MADE TO DATE. THE FAILURE MILEAGE WAS 10,000 AND THE CURRENT MILEAGE WAS 45,000.
I HAVE A 2006 FORD EXPEDITION WITH APPROX. 42,000 MILES. THE INCIDENT THAT OCCURRED WITH THIS VEHICLE, WHICH IS DANGEROUS, IS WHEN THE VEHICLE'S ENGINE FAILSAFE MODE ENGAGES. I WAS ACCELERATING FROM A STOP ON A TWO LANE ROAD WHEN THE ENGINE FAILSAFE MODE ENGAGED. WHEN THIS OCCURRED, I LOST THROTTLE CONTROL, ALMOST CAUSING ANOTH…
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I HAVE A 2006 FORD EXPEDITION WITH APPROX. 42,000 MILES. THE INCIDENT THAT OCCURRED WITH THIS VEHICLE, WHICH IS DANGEROUS, IS WHEN THE VEHICLE'S ENGINE FAILSAFE MODE ENGAGES. I WAS ACCELERATING FROM A STOP ON A TWO LANE ROAD WHEN THE ENGINE FAILSAFE MODE ENGAGED. WHEN THIS OCCURRED, I LOST THROTTLE CONTROL, ALMOST CAUSING ANOTHER VEHICLE TO STRIKE THE REAR OF MY VEHICLE. THE SECOND INCIDENT WAS ON DEC. 28, 2009. I WAS MAKING A LEFT TURN ONTO A SIDESTREET WHEN THE ENGINE FAILSAFE MODE OCCURRED AGAIN CAUSING ME TO LOSE CONTROL OF THE ACCELERATOR. I WAS ALMOST HIT BROADSIDE WHEN THIS INCIDENT OCCURRED. THE ONLY WAY TO REGAIN THROTTLE CONTROL IS TO TURN THE VEHICLE OFF AND RESTART THE VEHICLE. BY TURNING OFF THE VEHICLE IT ALSO RESETS THE ENGINE FAILSAFE MODE. UPON CHECKING THE ENGINE FAILSAFE MODE ON THE INTERNET, IT APPEARS TO BE A COMMON PROBLEM. SOMEONE SHOULD MAKE FORD FIX THIS PROBLEM BEFORE SOMEONE GETS SERIOUS INJURED OR KILLED. *TR
Official recalls
205V520000 · Visibility:windshield Wiper/washer:motor
Nov 9, 2005
ON CERTAIN TRUCKS, PASSENGER CARS AND SPORT UTILITY VEHICLES, THE WINDSHIELD WIPER MOTOR MAY HAVE BEEN PRODUCED WITHOUT GREASE BEING APPLIED TO THE OUTPUT SHAFT GEAR.
Consequence & remedy
Consequence: AFTER A PERIOD OF CONTINUOUS USE ON THE HIGH SPEED SETTING, LACK OF GREASE ON THE OUTPUT SHAFT GEAR MAY CAUSE THE GEAR TO DISTORT OR FRACTURE DURING OPERATION RESULTING IN A LOSS OF WIPER FUNCTION. INOPERATIVE WIPERS UNDER INCLEMENT WEATHER CONDITIONS COULD CAUSE A CRASH DUE TO IMPAIRED VISIBILITY.
Remedy: DEALERS WILL INSPECT THE WIPER MOTOR FOR THE PRESENCE OF GREASE AND GREASE THE WIPER MOTOR GEARS IF NECESSARY. THE RECALL BEGAN ON NOVEMBER 22, 2005. OWNERS MAY CONTACT FORD AT 1-800-392-3673 OR LINCOLN/MERCURY AT 1-800-521-4140.
05V310000 · Tires:tread/belt
Jul 6, 2005
ON CERTAIN SPORT UTILITY VEHICLES, THE FRONT AND REAR TIRES ON THE DRIVER'S SIDE OF AFFECTED VEHICLES MAY HAVE BEEN DAMAGED AT THE CENTER TREAD DURING PRODUCTION.
Consequence & remedy
Consequence: OVER TIME, THE DAMAGE MAY BE SUFFICIENT TO ALLOW BELT CORROSION ULTIMATELY LEADING TO A TREAD SEPARATION, WHICH COULD RESULT IN A CRASH.
Remedy: DEALERS WILL INSPECT ALL FOUR TIRES (TO ENSURE INSPECTION OF THE LEFT HAND SIDE TIRES THAT MAY HAVE BEEN ROTATED TO THE OTHER SIDE OF THE VEHICLE) FOR TIRE TREAD DAMAGE AND, IF NECESSARY, REPLACE THE DAMAGED TIRE. THE RECALL BEGAN ON JULY 13, 2005. OWNERS MAY CONTACT FORD AT 1-800-392-3673.
Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗
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