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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 →

When problems were reported

Mileage at the reported incident

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 reports
9,087 miles · Mar 12, 2007
Steering

TL* THE CONTACT OWNS A 2006 FORD EXPEDITION, EDDIE BAUER EDITION. THE VEHICLE WAS PURCHASED IN 03/2006. ON 10/15/06 THE CONTACT HEARD A LOUD NOISE AND EXPERIENCED VIBRATION IN THE STEERING WHEEL WHILE DRIVING SPEEDS RANGING FROM 5 TO 50MPH. ON 10/21/06 THE DEALER REPLACED THE STEERING RACK. THE FAILURE MILEAGE WAS 9,087. …

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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION, EDDIE BAUER EDITION. THE VEHICLE WAS PURCHASED IN 03/2006. ON 10/15/06 THE CONTACT HEARD A LOUD NOISE AND EXPERIENCED VIBRATION IN THE STEERING WHEEL WHILE DRIVING SPEEDS RANGING FROM 5 TO 50MPH. ON 10/21/06 THE DEALER REPLACED THE STEERING RACK. THE FAILURE MILEAGE WAS 9,087. THE NOISE AND THE VIBRATION CONTINUED TO OCCUR AFTER THE VEHICLE WAS REPAIRED. ON 11/13/06 THE STEERING RACK WAS REPLACED AGAIN FOR THE SAME FAILURE. TWO TO THREE DAYS AFTER THE VEHICLE WAS REPAIRED, THE NOISE AND VIBRATION REOCCURRED. THE DEALER WAS INFORMED OF THE FAILURE AND ADVISED THE CONTACT TO BRING THE VEHICLE IN TO DIAGNOSE IT ON 12/06/2006. THE DEALER ADVISED THE CONTACT THAT THEY WERE UNABLE TO REPAIR IT UNTIL A FORD ENGINEER INVESTIGATED THE FAILURE. ON 02/12/07, THE CONTACT RECEIVED A LETTER FROM THE DEALER STATING THAT THE FAILURE WAS NOT UNCOMMON FOR THIS TYPE OF VEHICLE. THE MANUFACTURER STATED THAT NO FURTHER ACTION WAS NEEDED. THE CONTACT FILED A LEMON LAW CASE IN HIS STATE WITH A COURT DATE FOR 09/28/07. ON TWO ATTEMPTS THE VEHICLE FAILED INSPECTION. THE CONTACT STATED THAT THIS WAS A SAFETY ISSUE ANDWAS REQUESTING THAT THE VEHICLE BE REPAIRED. THE CURRENT MILEAGE WAS 10,000. *AK

NHTSA ODI #10184818

11,000 miles · Mar 11, 2007
Power Train

AT ABOUT 11,000 MILES I HAD THE FIRST INCIDENT WHILE IN NORMAL TRAFFIC GOING ABOUT 45 MPH. FELT LIKE THE TRANSMISSION SLIPPED. NO POWER DURING 1ST AND 2ND GEAR CHANGE. A FEW DAYS LATER THE SAME THING HAPPEN WHILE ENTERING THE INTERSTATE. WHILE TRYING TO ACCELERATE THERE WAS NO POWER, NEARLY HIT BY SEMI-TRUCK, COULDN'T GET OV…

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AT ABOUT 11,000 MILES I HAD THE FIRST INCIDENT WHILE IN NORMAL TRAFFIC GOING ABOUT 45 MPH. FELT LIKE THE TRANSMISSION SLIPPED. NO POWER DURING 1ST AND 2ND GEAR CHANGE. A FEW DAYS LATER THE SAME THING HAPPEN WHILE ENTERING THE INTERSTATE. WHILE TRYING TO ACCELERATE THERE WAS NO POWER, NEARLY HIT BY SEMI-TRUCK, COULDN'T GET OVER 60 MPH AND THE CHECK ENGINE LIGHT CAME ON. I SLOWED BACK ON THE ACCELERATOR AND LIGHT WENT OFF AND POWER SLOWLY CAME BACK. TOOK VEHICLE TO FORD AT 12,000+ MILES, KEPT IT FOR SEVERAL DAYS. SAID IT WAS A COMPUTER MODULE, CHANGED IT, PICKED VEHICLE UP AND NOT 2 MILES DOWN THE ROAD THE SAME THING HAPPENED AGAIN. DIDN'T HAVE THE TIME TO TAKE IT RIGHT BACK IN NOT TO MENTION THERE RENTAL CAR EXPERIENCE WAS EQUALLY HORRIBLE. IT'S IN THEIR SHOP NOW 3/10 AND I'M AT 22,000 MILES AND IT HAPPENS EVERY TIME I ACCELERATE. IT'S A VERY DANGEROUS PROBLEM. NOW THEY SAY THEY THINK IT'S SOMETHING TO DO WITH THE TORQUE CONVERTER AND HAVE ORDERED PARTS. I'M ALSO HAVING A PROBLEM WITH IT NOT STARTING AFTER DRIVING, GETTING OUT AND GETTING BACK IN WITHIN ABOUT 30 MINUTES. WE'LL SEE NEXT WEEK WHAT THE OUTCOME IS! *JB

NHTSA ODI #10184734

13,000 miles · Jan 28, 2007
Service Brakes, HydraulicCrashInjury

BRAKES FAILED IN PANIC SITUATION ON DRY ROAD. BRAKES GRABBED AND THEN COMPLETELY LET GO WHEN ANTILOCK SYSTEM TOOK OVER. THERE WAS NO SURGE IN THE PEDAL AS IT WENT COMPLETELY TO THE FLOOR. MY ROAD SPEED WAS 35 MPH WHEN I HIT THE BRAKES AND I WOULD SAY THEIR WAS AT LEAST 100FT BETWEEN MINE AND THE STOPPED VEHICLE IN FRONT OF ME…

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BRAKES FAILED IN PANIC SITUATION ON DRY ROAD. BRAKES GRABBED AND THEN COMPLETELY LET GO WHEN ANTILOCK SYSTEM TOOK OVER. THERE WAS NO SURGE IN THE PEDAL AS IT WENT COMPLETELY TO THE FLOOR. MY ROAD SPEED WAS 35 MPH WHEN I HIT THE BRAKES AND I WOULD SAY THEIR WAS AT LEAST 100FT BETWEEN MINE AND THE STOPPED VEHICLE IN FRONT OF ME. I THOUGHT OF SWERVING TO MISS IT BUT WAS SURE I WOULD AT LEAST SLOW ENOUGH TO ONLY BUMP THE VEC. IN FRONT OF ME. THE GUY I HIT SAID HE HEARD A CHIRP AND A COUPLE SECONDS LATER GOT HIT. THERE WHERE NO SKID MARKS THAT I KNOW OF. THEIR WAS 21000 DOLLARS DAMAGE TO THE FRONT OF MY 2006 EXPIDITION. *NM

NHTSA ODI #10180943

8,000 miles · Jan 26, 2007
Power Train

WHEN EXITING INTERSTATE, CHANGES LANE AND AS GAS PETAL WAS PUSHED, NO POWER TO SUV, ENGINE DID NOT RACE OR SHAKE, JUST NO POWER. PUT SUV INTO FIRST GEAR AND IT JERKED AHEAD AT 10 MPH TO STOP LIGHT. WHILE STOPPED, SUV WOULD ROLL BACKWARD IF BRAKE NOT ON. MADE LEFT HAND TURN AND PUT BACK INTO GEAR, ABOUT ONE MILE LATER SAME LOSS O…

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WHEN EXITING INTERSTATE, CHANGES LANE AND AS GAS PETAL WAS PUSHED, NO POWER TO SUV, ENGINE DID NOT RACE OR SHAKE, JUST NO POWER. PUT SUV INTO FIRST GEAR AND IT JERKED AHEAD AT 10 MPH TO STOP LIGHT. WHILE STOPPED, SUV WOULD ROLL BACKWARD IF BRAKE NOT ON. MADE LEFT HAND TURN AND PUT BACK INTO GEAR, ABOUT ONE MILE LATER SAME LOSS OF POWER UNTIL PUT INTO 1ST GEAR. ONE MONTH LATER, ALSO WHILE EXITING INTERSTATE HAD SAME LOSS OF ALL POWER AT BOTTOM OF RAMP WHEN TRYING TO MERGE INTO LEFT LANE. SUV WOULD ONLY MOVE AFTER PUT INTO 1ST GEAR, ONLY AT 10 MPH. DEALERSHIP COULD FIND NOTHING WRONG AFTER A WEEK WITH THE FIRST INCIDENT, DEALER KEPT FOR 3 AND A HALF WEEKS AND THE P&S DIRECTOR DROVE 716 MILES AND COULD NOT DUPLICATE THIS PROBLEM. (NOTE BOTH HAPPEN WITHIN ONE WEEK OF DEALER OIL CHANGE) P&S DIRECTOR SUSPECTS FLY BY WIRE ISSUE, SAID THAT COMPARED TO OTHER 2005/2006 MODELS OURS HAS A DEAD PEDAL FEELING. *JB

NHTSA ODI #10180802

Mileage unknown · Dec 13, 2006
Unknown Or Other

ON A 2006 EXPEDITION, UPON START UP (NOT EVERY TIME) THERE IS A NOISE THAT I DESCRIBE AS WINDSHIELD WIPERS DRAGGING ACROSS A DRY WINDOW OR A WINDING SOUND THAT ALSO SOUNDS LIKE THE MOTOR OF THE WINDSHIELD WIPERS. IT SEEMS TO MAKE THIS NOISE AFTER THE VEHICLE HAS SAT FOR A PERIOD OF TIME, USUALLY AFTER A DAY AT WORK. BUT IT HAS…

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ON A 2006 EXPEDITION, UPON START UP (NOT EVERY TIME) THERE IS A NOISE THAT I DESCRIBE AS WINDSHIELD WIPERS DRAGGING ACROSS A DRY WINDOW OR A WINDING SOUND THAT ALSO SOUNDS LIKE THE MOTOR OF THE WINDSHIELD WIPERS. IT SEEMS TO MAKE THIS NOISE AFTER THE VEHICLE HAS SAT FOR A PERIOD OF TIME, USUALLY AFTER A DAY AT WORK. BUT IT HAS MADE THIS NOISE FIRST THING IN THE MORNING AFTER SITTING ALL NIGHT. IT HAS NEVER DONE IT ON A SECOND IMMEDIATE START UP. FORD HAS REPLACED THE STARTER, NO HELP. FORD HAS REPLACED THE SPARK PLUGS (THIS WAS A 2005 RECALL I WAS TOLD), NO HELP AND THEY HAVE REPLACED THE OIL FILTER, AGAIN NO HELP. UNFORTUNATELY NO-ONE AT FORD HAS HEARD THIS NOISE, BUT ONE TECH SEEMED TO KNOW ABOUT IT FROM ANOTHER CUSTOMER WITH THE SAME ISSUE. I HAVE MADE SUGGESTIONS TO THE FORD TECH'S SO THAT THEY COULD EXPERIENCE THIS SAME EVENT (THAT WENT ON DEAF EARS), THEY HAVE LOTS OF THOUGHTS THAT IT COULD BE THE BLENDER (SP) AND THAT I SHOULD NOT TURN THE A/C ON UPON START UP. I TRIED THAT AS WELL, I WILL TRY ANY SUGGESTION THEY PUT OUT, BUT STILL THE SAME NOISE. THEY HAVE THOUGHTS ABOUT THE CAM, AND THEY STOOD THERE AND AGREED THAT THE OIL FILTER CHANGE WOULD NOT FIX THE PROBLEM. BUT WHAT THE HECK TRY IT. FORD HAS STATED THAT THEY CAN NOT KEEP THE VEHICLE TO TRY AND FIND OUT WHAT IS WRONG. I AM VERY CONCERNED THAT THIS IS GOING TO BECOME SOMETHING BIGGER AND FAR WORSE. I FEAR OF A FIRE IN THE VEHICLE. SINCE FORD DOES NOT WANT TO TAKE THE TIME TO TRY AND ISOLATE THE PROBLEM I SUGGESTED THEY PUT IN WRITING AN EXTENDED WARRANTY ON THIS VEHICLE. *NM

NHTSA ODI #10176009

17,000 miles · Oct 30, 2006
Electrical SystemFire

VEHICLE HAD BEEN DISPLAYING THE LOW AIR PRESSURE LIGHT AND THE CHECK ENGINE LIGHT ( SMOG CONTROL). TIRES WERE CHECKED AND FOUND TO BE PROPERLY INFLATED, ALL FLUIDS, FILTERS, ETC, WERE CHECKED AND FOUND TO BE IN WORKING ORDER. VEHICLE WAS DRIVEN APPROXIMATELY 15-20 MILES. BOTH BEFORE MENTION LIGHTS CONTINUED TO COME ON AND OFF. V…

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VEHICLE HAD BEEN DISPLAYING THE LOW AIR PRESSURE LIGHT AND THE CHECK ENGINE LIGHT ( SMOG CONTROL). TIRES WERE CHECKED AND FOUND TO BE PROPERLY INFLATED, ALL FLUIDS, FILTERS, ETC, WERE CHECKED AND FOUND TO BE IN WORKING ORDER. VEHICLE WAS DRIVEN APPROXIMATELY 15-20 MILES. BOTH BEFORE MENTION LIGHTS CONTINUED TO COME ON AND OFF. VEHICLE WAS PARKED. APPROX 1 HOUR LATER VEHICLE HORN SOUNDED, I WALKED TO CHECK HORN AND FOUND THE VEHICLE INTERIOR IN FLAMES. I WAS ABLE TO PUT THE FIRE OUT, AND KEEP THE DAMAGE TO THE DRIVERS SIDE DASH, STEERING AREA. VEHICLE INTERIOR SUFFERED HEAVY SMOKE DAMAGE, FRONT WINDSHIELD CRACKED. CONTACTED INSURANCE COMPANY AND FORD MOTOR COMPANY. VEHICLE IS ONLY 9 MONTHS OLD AND STILL UNDER WARRANTY. I REQUESTED THAT FORD REPLACE MY VEHICLE WITH ANOTHER VEHICLE JUST LIKE I PURCHASED. FORD SENT LETTER SAYING THAT SINCE INSURANCE COMPANY IS INVOLVED THEY PROPOSE NO FURTHER ACTION. BUT SINCE VEHICLE IS USED, INSURANCE COMPANY WILL ONLY PAY FAIR MARKET VALUE, LEAVING ME TO PAY FOR THE BALANCE. ALL I WANT IS FOR FORD TO REPLACE MY DEFECTIVE VEHICLE. *JB

NHTSA ODI #10172196

700 miles · Oct 4, 2006
SteeringCrash

WHILE MAKING A HARD LEFT TURN TO AVOID A CRASH , I WAS UNABLE TO RECOVER TO THE RIGHT EVEN WITH MY STEERING WHEEL TURNED AL THE WAY TO THE RIGHT. MY VEHICLE CONTINUED LEFT AND COLLIDED WITH THE GUARD RAIL AT ABOUT THIRTY MPH. INSPECTION OF THE DAMAGE FOUND THAT THE LEFT FRONT TIE ROD ON MY BRAND NEW EXPEDITION WAS BROKEN IN HAL…

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WHILE MAKING A HARD LEFT TURN TO AVOID A CRASH , I WAS UNABLE TO RECOVER TO THE RIGHT EVEN WITH MY STEERING WHEEL TURNED AL THE WAY TO THE RIGHT. MY VEHICLE CONTINUED LEFT AND COLLIDED WITH THE GUARD RAIL AT ABOUT THIRTY MPH. INSPECTION OF THE DAMAGE FOUND THAT THE LEFT FRONT TIE ROD ON MY BRAND NEW EXPEDITION WAS BROKEN IN HALF. THERE WAS MARKS ON THE TIE ROD TO INDICATE THAT IT WAS CUT. INSTEAD IT WAS FRACTURED . THIS IS THE REASON FOR LOSS OF STEERING CONTROL. *NM

NHTSA ODI #10169925

3,500 miles · Sep 12, 2006
Equipment

THE AIR CONDITIONING SYSTEM WORKS FINE WHEN THE VEHICLE IN MOTION (AT HIGHER THAN IDLE RPM), BUT SEEMS TO BLOW DISTINCTLY WARMER WHEN AT IDLE( E.G. AT A STOP LIGHT). BROUGHT IN TO THE DEALER TWICE AND WAS TOLD THERE IS NOTHING WRONG, THAT THE COMPRESSOR FAN IS TURNING SLOWER AT IDLE. IF THIS IS TRUE IT IS AN OBVIOUS DESIGN F…

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THE AIR CONDITIONING SYSTEM WORKS FINE WHEN THE VEHICLE IN MOTION (AT HIGHER THAN IDLE RPM), BUT SEEMS TO BLOW DISTINCTLY WARMER WHEN AT IDLE( E.G. AT A STOP LIGHT). BROUGHT IN TO THE DEALER TWICE AND WAS TOLD THERE IS NOTHING WRONG, THAT THE COMPRESSOR FAN IS TURNING SLOWER AT IDLE. IF THIS IS TRUE IT IS AN OBVIOUS DESIGN FLAW. WE HAVE HAD PREVIOUS MODEL YEARS OF THIS MODEL AND NOT HAD THIS PROBLEM. *JB

NHTSA ODI #10168096

Mileage unknown · Aug 11, 2006
Electrical SystemInjury

I BOUGHT A 2006 FORD EXPEDITION AND 3 MONTHS LATER WHILE MY DAD WAS DRIVING IT ACCELERATED BY IT SELF AND MY DAD DIE IN THE ACCIDENT CAUSED BY UNEXPECTED ACCELERATION OF THE VEHICLE. *NM

NHTSA ODI #10165260

800 miles · Aug 10, 2006
Engine And Engine CoolingEquipment

LOUD GRINDING NOISE ON INITIAL START UP ON 2006 FORD EXPEDITION, FORD MOTOR CLAIMS IT IS FROM A/C COMPRESSOR, YET, CANNOT GIVE ME A WRITTEN GUARANTEE THAT THE VEHICLE WILL NOT CATCH ON FIRE, BLOW UP OR STALL. VEHICLE SITTING ON DEALER LOT BECAUSE I AM AFRAID TO DRIVE IT. *JB

NHTSA ODI #10165109

Official recalls

2

05V520000 · 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

1

PE08070 · 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