IllustrationTHE TRANSMISSIONS OVERDRIVE (84,000 ) STOP WORKING EFFICIENTLY WITHOUT ANY SIGNAL OF PROBLEM. WHEN IN MOTION REACHING 35 MILES/HOUR THE TRANSMISSION STOPS.
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 reportsAT APPROXIMATELY 45 MILES AN HOUR THERE IS A GRINDING NOISE THAT SOUNDS LIKE THE TRANSMISSION. IF I SPEED UP IT GOES AWAY. AFTER DRIVE FOR AWHILE THE OVERDIVE LIGHT STARTS TO BLINK. IF I TURN OFF THE ENGINE THE LIGHT STOPS BLINKING. THE CAR PERFORMS MUCH BETTER WITH THE OVERDIVE OFF. HAD THE TRANSMISSION REBUILT AND IT DIDN'T SO…
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AT APPROXIMATELY 45 MILES AN HOUR THERE IS A GRINDING NOISE THAT SOUNDS LIKE THE TRANSMISSION. IF I SPEED UP IT GOES AWAY. AFTER DRIVE FOR AWHILE THE OVERDIVE LIGHT STARTS TO BLINK. IF I TURN OFF THE ENGINE THE LIGHT STOPS BLINKING. THE CAR PERFORMS MUCH BETTER WITH THE OVERDIVE OFF. HAD THE TRANSMISSION REBUILT AND IT DIDN'T SOLVE THE PROBLEM. THE TRANSMISSION SHOP SAYS THE PROBLEM IS NOT IN THE TRANSMISSUON ITSELF. FORD DEALER RECOMMENDED CHANGING THE TROTTLE SENSON, $100 LATER THAT DIDN'T WORK. MECHANICS IN TOWN CAN'T FIGURE IT OUT. IT SOUNDS LIKE 2 GEARS TRYING TO ENGAGE, THUS THE GRINDING NOISE. WHEN I DRIVE WITH THE OVERDRIVE OFF IT HAPPENS AT A HIGHER SPEED. ALWAYS HAPPENS WHEN DRIVI G UP A LONG INCLINE. GOING CRAZY WITH THIS PROBLEM.
TL* THE CONTACT OWNED A 2006 FORD EXPEDITION. WHILE DRIVING APPROXIMATELY 45-50 MPH, THE VEHICLE SUDDENLY HYDROPLANED AND CRASHED INTO A CONCRETE WALL OFF TO THE SIDE OF THE ROAD. THE VEHICLE SPUN AROUND 8-10 TIMES AND CRASHED INTO THE WALL APPROXIMATELY AN ADDITIONAL FIVE TIMES. THE VEHICLE EVENTUALLY WENT BACK ONTO THE ROAD FA…
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TL* THE CONTACT OWNED A 2006 FORD EXPEDITION. WHILE DRIVING APPROXIMATELY 45-50 MPH, THE VEHICLE SUDDENLY HYDROPLANED AND CRASHED INTO A CONCRETE WALL OFF TO THE SIDE OF THE ROAD. THE VEHICLE SPUN AROUND 8-10 TIMES AND CRASHED INTO THE WALL APPROXIMATELY AN ADDITIONAL FIVE TIMES. THE VEHICLE EVENTUALLY WENT BACK ONTO THE ROAD FACING ONCOMING TRAFFIC. THE CONTACT RESTARTED THE VEHICLE TO MOVE TO THE SIDE OF THE ROAD AND THE INJECTORS FOR THE PASSENGER SIDE AIR BAG RELEASED; HOWEVER, THE PASSENGER AND DRIVER SIDE AIR BAGS DID NOT DEPLOY. THE VEHICLE WAS DESTROYED AND TOWED. A POLICE REPORT WAS FILED. THE CHILD IN THE REAR WAS EJECTED FROM THE SAFETY SEAT, THE PASSENGER RECEIVED INJURIES TO THE ARM, BACK, AND NECK AREA, AND THE CONTACT RECEIVED INJURIES TO THE BACK, LEG, PELVIC, WRIST, AND HEAD INJURIES. MEDICAL ATTENTION WAS NEEDED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND OPENED CASE NUMBER: CAS12509910. THE APPROXIMATE FAILURE MILEAGE WAS 160,000.
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. WHILE DRIVING OR WHILE THE VEHICLE WAS IDLING, THE CONTACT HEARD A TICKING NOISE COMING FROM THE ENGINE. THERE WERE NO WARNING INDICATORS ILLUMINATED. THE VEHICLE WAS TAKEN TO THE DEALER (KEN GRODY FORD AT 6211 BEACH BLVD, BUENA PARK, CA 90621) WHERE IT WAS DIAGNOSED THAT THE VALVE LA…
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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. WHILE DRIVING OR WHILE THE VEHICLE WAS IDLING, THE CONTACT HEARD A TICKING NOISE COMING FROM THE ENGINE. THERE WERE NO WARNING INDICATORS ILLUMINATED. THE VEHICLE WAS TAKEN TO THE DEALER (KEN GRODY FORD AT 6211 BEACH BLVD, BUENA PARK, CA 90621) WHERE IT WAS DIAGNOSED THAT THE VALVE LASH ADJUSTER AND THE TIMING CHAIN TENSIONERS NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER INFORMED THE CONTACT TO CALL NHTSA AND DID NOT OFFER ANY FURTHER ASSISTANCE. THE FAILURE MILEAGE WAS 100,464.
WHILE IN TRAFFIC, AT LEAST 100 TIMES IN THE LAST FOUR YEARS (AT VARIABLE SPEEDS FROM 5 TO 65 MPH ON CITY STREETS AND FREEWAYS) MOST RECENTLY TWICE IN THE LAST WEEK, THE RPMS DROP BELOW 500 AND THE VEHICLE DIES AND "ENGINE FAILSAFE MODE" LIGHTS UP ON THE DASH. I HAVE TO EITHER COAST TO PULL OVER OR DEAD STOP IN THE MIDDLE OF THE …
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WHILE IN TRAFFIC, AT LEAST 100 TIMES IN THE LAST FOUR YEARS (AT VARIABLE SPEEDS FROM 5 TO 65 MPH ON CITY STREETS AND FREEWAYS) MOST RECENTLY TWICE IN THE LAST WEEK, THE RPMS DROP BELOW 500 AND THE VEHICLE DIES AND "ENGINE FAILSAFE MODE" LIGHTS UP ON THE DASH. I HAVE TO EITHER COAST TO PULL OVER OR DEAD STOP IN THE MIDDLE OF THE ROAD. I HAVE TO TURN THE VEHICLE COMPLETELY OFF (EVEN THOUGH IN FAILSAFE MODE ENGINE IS OFF, THE ELECTRONICS ARE STILL ON) AND THEN RESTART AND THEN IT WILL DRIVE JUST FINE UNTIL IT HAPPENS AGAIN. IT HAPPENS ANYWHERE FROM ONCE EVERY 6 MONTHS TO 6 TIMES IN 1 WEEK. IT SEEMS AS THOUGH IF I DRIVE WITH BOTH FEET IN TRAFFIC AND MAINTAIN ABOUT 800-1000 RMPS AT ALL TIMES IT DOESN'T DO THIS, HOWEVER THIS CANNOT BE DONE ALL THE TIME ESPECIALLY WHEN TRYING TO STOP THE LARGE VEHICLE QUICKLY OR TURNING IN AN INTERSECTION. NOTHING HAS BEEN DIAGNOSED BY DEALERSHIP AS NO CODES ARE THROWN. I ALSO OWN A OBD2 READER AND NO CODES HAVE EVER LISTED UNLESS ITS TIME TO CHANGE THE SPARK PLUGS. SEVERAL DIFFERENT MECHANICS, FORUMS AND BRAINSTORMING HAS NOT FIGURED IT OUT. I HAVE REPLACED MOSTLY EVERYTHING WITH EXCEPTION TO A NEW TRANSMISSION AND COMPUTER. MOSTLY EVERYTHING INCLUDING WIRES AND VACUUM LINES AND GASKETS HAVE BEEN REPLACED DUE TO MAINTENANCE OR REPAIRS FROM EVERYTHING ELSE THAT HAS GONE WRONG WITH IT. I HAVE PUT ABOUT $10K INTO NEW PARTS FOR THIS VEHICLE. I BOUGHT IT WITH 60K MILES ON IT AND IT NOW HAS 117K, ITS A DAILY DRIVER WITH 28 MILES OF TRAVEL 5 DAYS A WEEK. ALSO THE ONLY VEHICLE THAT FITS ALL OF THE CHILDREN FOR SOCCER, TRACK AND VOLLEYBALL TRAVELING TOURNAMENTS/GAMES. LUCKILY IT DOESN'T HAPPEN VERY OFTEN WHEN I'M NOT IN TRAFFIC SO THE KIDS AREN'T USUALLY WITH ME BUT IT IS VERY SCARY NOT TO KNOW IF YOU ARE GOING TO STOP OR IF THE PEOPLE BEHIND YOU ARE GOING TO HIT YOU OR NOT.
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT WHILE THE DRIVER WAS DRIVING AT AN UNKNOWN SPEED, THE VEHICLE STALLED AS THE FAIL SAFE MODE WARNING MESSAGE ILLUMINATED ACROSS THE INSTRUMENT PANEL. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE…
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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT WHILE THE DRIVER WAS DRIVING AT AN UNKNOWN SPEED, THE VEHICLE STALLED AS THE FAIL SAFE MODE WARNING MESSAGE ILLUMINATED ACROSS THE INSTRUMENT PANEL. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 194,000.
ENGINE FAIL SAFE MODE ENGAGES AT VARIOUS AND UNPREDICTABLE SPEEDS AND AT ANY GIVEN TIME. IT HAS HAPPENED NUMEROUS TIMES AND SHOWS NO CODE AFTERWARDS. A VERY DANGEROUS ISSUE THAT NEEDS TO BE ADDRESSED BY FORD. I HAVE FOUND THOUSANDS OF COMPLAINTS ABOUT THIS ISSUE BUT I CAN FIND NO INDICATION THAT FORD HAS BEEN WILLING TO ADDRESS…
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ENGINE FAIL SAFE MODE ENGAGES AT VARIOUS AND UNPREDICTABLE SPEEDS AND AT ANY GIVEN TIME. IT HAS HAPPENED NUMEROUS TIMES AND SHOWS NO CODE AFTERWARDS. A VERY DANGEROUS ISSUE THAT NEEDS TO BE ADDRESSED BY FORD. I HAVE FOUND THOUSANDS OF COMPLAINTS ABOUT THIS ISSUE BUT I CAN FIND NO INDICATION THAT FORD HAS BEEN WILLING TO ADDRESS THE ISSUE. WHEN ASKED FOR THE DATE THE INCIDENT HAPPENED I AM ENTERING THE DATE OF COMPLAINT BECAUSE THIS HAS HAPPENED MULTIPLE TIMES. NO CODES DOES NOT MEAN THE VEHICLE DOESN'T HAVE ISSUES. FORD NEEDS TO ADDRESS THIS ISSUE....RECALL AND CORRECT THE PROBLEM.
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. WHILE DRIVING AT VARIOUS SPEEDS AND AFTER A LOUD ALARM SOUND, THE VEHICLE STALLED AND THE ENGINE WARNING LIGHT ILLUMINATED. THE VEHICLE WAS TAKEN TO THE DEALER WHERE THE SPARK PLUGS WERE REPLACED AND THE MECHANIC INFORMED THE CONTACT THAT THE CATALYTIC CONVERTER WAS FAILING. THE FAILU…
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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. WHILE DRIVING AT VARIOUS SPEEDS AND AFTER A LOUD ALARM SOUND, THE VEHICLE STALLED AND THE ENGINE WARNING LIGHT ILLUMINATED. THE VEHICLE WAS TAKEN TO THE DEALER WHERE THE SPARK PLUGS WERE REPLACED AND THE MECHANIC INFORMED THE CONTACT THAT THE CATALYTIC CONVERTER WAS FAILING. THE FAILURE HAD REOCCURRED ON SEVERAL OCCASIONS. THE FAILURE MILEAGE WAS 80,000.
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. WHILE DRIVING OVER 50 MPH, THE VEHICLE SHOOK VIGOROUSLY AND THE CHECK ENGINE WARNING INDICATOR ILLUMINATED. THE VEHICLE WAS TAKEN TO A DEALER, BUT WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 135,000.
"TAKATA RECALL" THERE IS A LOUD VIBRATION COMING FROM PASSENGER SIDE OF DASHBOARD. I HAVE TAKEN THE VEHICLE IN TO BE INSPECTED AND WAS TOLD THERE IS A LEAK IN MY AIR BAG AND THAT UPON COLLISION THE AIR BAG MAY NOT DEPLOY.
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