NHTSA owner reports · September 18, 2026 snapshot.
What owners actually said
299 reports75,000 miles · Oct 8, 2015
Engine
WE WERE EXPERIENCING STALLS AND OVERALL SLUGGISHNESS AND TOOK IT TO A MECHANIC WHO TOLD US WE NEEDED A TUNE UP. MY HUSBAND USUALLY DOES MINOR UPKEEP, THANKED THE MAN AND WAS ABOUT TO TAKE OUR TRUCK HOME WHEN THE MECHANIC INFORMED US THAT THE PLUGS WERE A BEAR TO CHANGE SINCE WE WOULD NEED A SPECIAL TOOL AND CHANCES ARE, THE PLU…
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WE WERE EXPERIENCING STALLS AND OVERALL SLUGGISHNESS AND TOOK IT TO A MECHANIC WHO TOLD US WE NEEDED A TUNE UP. MY HUSBAND USUALLY DOES MINOR UPKEEP, THANKED THE MAN AND WAS ABOUT TO TAKE OUR TRUCK HOME WHEN THE MECHANIC INFORMED US THAT THE PLUGS WERE A BEAR TO CHANGE SINCE WE WOULD NEED A SPECIAL TOOL AND CHANCES ARE, THE PLUGS WOULD BREAK OFF. WE WERE SKEPTICAL BUT TRUSTED HIM TO DO THE JOB. IT COST SO MUCH AND TOOK SO LONG, WE BOUGHT A BEATER CAR IN THE INTERIM SO WE COULD GET TO WORK! AND IT COST OVER $1000...FOR A TUNE UP!!! IT LOOKS LIKE FORD KNOWS FULL WELL ABOUT THIS BUILT IN MONEY MAKER SINCE I SEE WE ARE IN GOOD COMPANY WITH MANY OWNERS COMPLAINING ABOUT THE EXACT SAME ISSUE. SHAME ON FORD.
NHTSA ODI #10780878
Mileage unknown · Oct 5, 2015
Fuel/propulsion System
IT TAKES FOREVER TO DRIBBLE GAS INTO THE TANK AT THE FILLING STATION; THE BACK PRESSURE IN THE FILLER PIPE CUTS OUT THE PUMP SO BAD IT TAKES OVER 20 MINUTES TO FILL THE LARGE TANK; THIS IS UNACCEPTABLE IN BAD WEATHER AND MORE THAN ANNOYING ON A TIGHT SCHEDULE AS IT ENCOURAGES SPEEDING TO MAKE UP FOR LOST TIME!
NHTSA ODI #10779940
140,000 miles · Sep 29, 2015
Electrical SystemSteeringVehicle Speed Control
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT THE VEHICLE STALLED. ON ANOTHER OCCASION, THE VEHICLE STALLED AFTER THE VEHICLE ENGINE SAFETY MODE WAS INITIATED WHILE DRIVING APPROXIMATELY 5 MPH. THE VEHICLE WAS RESTARTED BUT THE FAILURE RECURRED FIVE MINUTES LATER. THE VEHICLE WAS TAKEN TO A DEALER WHERE IT…
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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT THE VEHICLE STALLED. ON ANOTHER OCCASION, THE VEHICLE STALLED AFTER THE VEHICLE ENGINE SAFETY MODE WAS INITIATED WHILE DRIVING APPROXIMATELY 5 MPH. THE VEHICLE WAS RESTARTED BUT THE FAILURE RECURRED FIVE MINUTES LATER. THE VEHICLE WAS TAKEN TO A DEALER WHERE IT WAS DIAGNOSED THAT THE THROTTLE BODY SENSOR NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 140,000.
NHTSA ODI #10778348
135,000 miles · Aug 14, 2015
Unknown Or Other
MY 2006 FORD EXPEDITION WAS PARKED IN MY DRIVEWAY AT 7:00 AM WHEN I HEARD A CRASH. I LOOKED OUT THE WINDOW TO SEE THE BACK LIFT GATE GLASS HAD EXPLODED, ALL ELSE IN MY NEIGHBORHOOD WAS QUIET AT THAT HOUR. AS FAR AS I CAN TELL NO IMPACT FROM AN EXTERNAL SOURCE, IT WAS BACKED IN CLOSE TO A BOAT. I HAD DRIVEN THE VEHICLE TWO DAY…
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MY 2006 FORD EXPEDITION WAS PARKED IN MY DRIVEWAY AT 7:00 AM WHEN I HEARD A CRASH. I LOOKED OUT THE WINDOW TO SEE THE BACK LIFT GATE GLASS HAD EXPLODED, ALL ELSE IN MY NEIGHBORHOOD WAS QUIET AT THAT HOUR. AS FAR AS I CAN TELL NO IMPACT FROM AN EXTERNAL SOURCE, IT WAS BACKED IN CLOSE TO A BOAT. I HAD DRIVEN THE VEHICLE TWO DAYS PRIOR AND HAD NOTICED NO PROBLEM WITH THE REAR WINDOW. WHEN I CLEANED UP THE MESS I FOUND A GOOD AMOUNT OF THE SMALL GLASS PIECES WERE INSIDE THE VEHICLE, THE REMAINDER WERE ON THE GROUND BEHIND THE VEHICLE WITHIN TEN FEET OR SO. THE LARGEST PIECES OF GLASS WERE SMALLER THAN MY PALM.
NHTSA ODI #10748723
111,000 miles · Jul 31, 2015
Engine
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. WHILE PARKED, THE VEHICLE STALLED SHORTLY AFTER BEING STARTED. THE CONTACT WAS ABLE TO RESTART THE VEHICLE, BUT THE ENGINE WARNING INDICATOR ILLUMINATED. THIS WAS A RECURRING FAILURE. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE APPR…
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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. WHILE PARKED, THE VEHICLE STALLED SHORTLY AFTER BEING STARTED. THE CONTACT WAS ABLE TO RESTART THE VEHICLE, BUT THE ENGINE WARNING INDICATOR ILLUMINATED. THIS WAS A RECURRING FAILURE. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 111,000.
NHTSA ODI #10745352
194,549 miles · Jul 9, 2015
Engine
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. WHILE DRIVING 60 MPH, THE VEHICLE MADE A RATTLING NOISE. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHERE IT WAS DIAGNOSED THAT THE VEHICLE'S ENGINE NEEDED TO BE REPAIRED OR REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEA…
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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. WHILE DRIVING 60 MPH, THE VEHICLE MADE A RATTLING NOISE. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHERE IT WAS DIAGNOSED THAT THE VEHICLE'S ENGINE NEEDED TO BE REPAIRED OR REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 194,549.
NHTSA ODI #10733064
164,500 miles · Jul 1, 2015
Engine
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. WHILE DRIVING 65 MPH, THE ENGINE WARNING LIGHT ILLUMINATED AND FLICKERED WHEN ACCELERATING. THE FAILURE RECURRED INTERMITTENTLY. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 164,500.
NHTSA ODI #10731606
Mileage unknown · May 1, 2015
Engine
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING AT AN UNKNOWN SPEED, THE VEHICLE JERKED AND LOST POWER AS THE CHECK ENGINE WARNING LIGHT ILLUMINATED. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC, WHO DIAGNOSED THAT THE ENGINE NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACT…
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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING AT AN UNKNOWN SPEED, THE VEHICLE JERKED AND LOST POWER AS THE CHECK ENGINE WARNING LIGHT ILLUMINATED. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC, WHO DIAGNOSED THAT THE ENGINE NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS UNKNOWN.
NHTSA ODI #10714059
135,000 miles · May 1, 2015
Electrical SystemEngine
FIRST OCCURRENCE EXHIBITED FLICKERING DASHBOARD LIGHTS BEFORE THE ELECTRICAL SYSTEM WENT COMPLETELY DEAD AND THE ENGINE QUIT WHILE ACCELERATING AT APPROXIMATELY 20 MPH. PUT VEHICLE IN NEUTRAL AND WAS ABLE TO RESTART ENGINE NORMALLY BEFORE COMING TO A STOP. HAVE EXPERIENCED SEVERAL SHORT INSTANCES OF DASH FLICKERING OVER THE PA…
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FIRST OCCURRENCE EXHIBITED FLICKERING DASHBOARD LIGHTS BEFORE THE ELECTRICAL SYSTEM WENT COMPLETELY DEAD AND THE ENGINE QUIT WHILE ACCELERATING AT APPROXIMATELY 20 MPH. PUT VEHICLE IN NEUTRAL AND WAS ABLE TO RESTART ENGINE NORMALLY BEFORE COMING TO A STOP. HAVE EXPERIENCED SEVERAL SHORT INSTANCES OF DASH FLICKERING OVER THE PAST COUPLE OF WEEKS WITH NO APPARENT ENGINE PROBLEMS. DURING THAT SAME PERIOD THERE HAVE BEEN APPROXIMATELY 4 INSTANCES OF THE ELECTRICAL SYSTEM BEING COMPLETELY DEAD UPON THE INITIAL ATTEMPT TO START THE ENGINE. WHEN THIS HAPPENS, THE ONLY LIGHT THAT IS ILLUMINATED ON THE DASH (OR ANYWHERE ELSE FOR THAT MATTER) IS WHAT I THINK IS THE AIRBAG LIGHT; HOWEVER, NORMAL ELECTRICAL POWER HAS, THUS FAR, RE-APPEARED WITHIN 5 MINUTES AND THE ENGINE THEN STARTS AND RUNS NORMALLY. YESTERDAY THE "CHECK ENGINE" LIGHT CAME ON AND I WAS ABLE TO PULL A CODE OF P0119 (ENGINE COOLANT TEMPERATURE CIRCUIT INTERMITTENT) UPON RETURNING HOME. I SUBSEQUENTLY CLEARED THE CODE, BUT THE READER INDICATES ANOTHER CODE IS "PENDING". I BELIEVE THIS IS A SYMPTOM OF A LARGER PROBLEM. I HAVE NOT EXPERIENCED A "ENGINE FAILSAFE MODE" WARNING MESSAGE, BUT THIS COMPLAINT IS VERY SIMILAR TO MANY OTHERS ALREADY POSTED AND I AGREE WITH THE RELATED SAFETY CONCERNS AND NEED FOR A RECALL. *TR
NHTSA ODI #10714028
106,556 miles · Mar 24, 2015
Engine
DRIVING DOWN HIGHWAY AT 45 MPH WHEN ENGINE FAIL SAFE MODE CAME ON. WITH NO POWER, HAD TO VEER OFF TO A TURN LANE PUT IN PARK AND RESTART CAR. THIS IS THE SECOND TIME THIS HAS HAPPENED. FIRST WAS ON HIGHWAY AS WELL AROUND 40 MPH, SAME THING HAPPENED; NO POWER HAD TO VEER OFF TO THE SIDE OF THE HIGHWAY, PARK AND RESTART CAR. EXTRE…
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DRIVING DOWN HIGHWAY AT 45 MPH WHEN ENGINE FAIL SAFE MODE CAME ON. WITH NO POWER, HAD TO VEER OFF TO A TURN LANE PUT IN PARK AND RESTART CAR. THIS IS THE SECOND TIME THIS HAS HAPPENED. FIRST WAS ON HIGHWAY AS WELL AROUND 40 MPH, SAME THING HAPPENED; NO POWER HAD TO VEER OFF TO THE SIDE OF THE HIGHWAY, PARK AND RESTART CAR. EXTREMELY DANGEROUS TO BE DRIVING ON A BUSY HIGHWAY AND HAVE EXPEDITION SHUT OFF COMPLETELY. *TR
NHTSA ODI #10701390
NHTSA investigations
1PE08070 · Steel Wheel Fracture
Opened Dec 9, 2008 · Closed Apr 15, 2009
Status: closed (inferred from source dates) · Wheels; Wheels:rim
FORD SPECIAL SERVICE VEHICLE (SSV) EXPEDITIONS USE A STEEL FULL FACE WHEEL DESIGN SIMILAR TO THAT INVESTIGATED IN PE03009, RQ04007, EA04034 (CROWN VICTORIA POLICE INTERCEPTOR) AND PE03026 (GM PICKUPS AND SUVS).A TOTAL OF 8,251 SSVS (2.2% OF TOTAL PRODUCTION) WERE PRODUCED WITHIN MODEL YEARS 2004-2006 AND SOLD PRIMARILY FOR USE BY STATE, FEDERAL, AND MUNICIPAL LAW ENFORCEMENT (LE) AGENCIES.FORD STIPULATES THAT THE SUBJECT VEHICLES ARE NOT SUITABLE FOR HIGH SPEED OR PURSUIT OPERATIONS AND ALSO IDENTIFIED A 2004 NATIONAL INSTITUTE FOR JUSTICE VEHICLE EVALUATION REPORT WHICH ALSO ACKNOWLEDGES THIS LIMITATION. THE FULL FACE WHEEL IS FABRICATED FROM TWO PIECES: A STAMPED OUTER WHEEL DISC AND A FORMED RIM.THE TWO PIECES, WHICH TOGETHER COMPRISE THE OUTER BEAD SEAT, ARE JOINED TOGETHER WITH A CIRCUMFERENTIAL WELD.A CYCLIC BENDING MOMENT OCCURS IN THE OUTER BEAD SEAT AREA AS THE WHEEL ROTATES, RESULTING IN FATIGUE STRESSES IN THE WELD'S HEAT AFFECTED ZONE THAT CAN LEAD TO FRACTURING (CRACKING) OF THE RIM MATERIAL.BECAUSE THE FAILURE OCCURS UNDER THE OUTBOARD TIRE BEAD, AIR LEAKAGE MAY NOT READILY OCCUR WHEN THE RIM CRACKS, DEPENDENT ON HOW WELL THE BEAD SEALS ON THE RIM.IF MULTIPLE CRACKS GROW UNDETECTED AND SUDDENLY JOIN INTO A SINGLE LARGE CRACK, THE WHEEL'S STRUCTURE CAN BECOME COMPROMISED LEADING TO RAPID AIR LOSS.A RAPID AIR LOSS, ESPECIALLY AT HIGHER SPEED, MAY LEAD TO A CRASH. FORD RESPONDED TO ODI'S JANUARY 5, 2009 INFORMATION REQUEST (IR) ON FEBRUARY 24.FORD'S RESPONSE ACKNOWLEDGES A NUMBER OF WHEEL FRACTURES ON THE SSVS.HOWEVER, BASED ON ITS ASSESSMENT OF THE PERTINENT FACTORS, IT CONCLUDES THAT THE CONDITION DOES NOT REPRESENT AN UNREASONABLE RISK TO SAFETY.THE LACK OF REPORTS OF RAPID AIR LOSS, NO ALLEGED CRASHES, AND THEIR ASSESSMENT THAT A CRACKED WHEEL CAN BE DETECTED THROUGH SLOW, REPEATED AIR LOSS OR VIBRATION, WERE THE BASES FOR FORD'S CONCLUSION.FORD DISCUSSES THE RESULTS OF A STUDY IT PERFORMED ON WHEELS RETURNED FROM LE FIELD USE, DESIGN REVISIONS IT MADE TO THE SUBJECT WHEEL, AND THE OUTCOME OF DURABILITY TESTING IT CONDUCTED ON THE OLD AND NEW WHEEL DESIGNS. THE COUNTS SHOWN ABOVE INCLUDE A DUPLICATE ODI AND FORD REPORT; THE FORD COUNTS ARE UNIQUE VEHICLES ALLEGING WHEEL FRACTURE(S).SOME WARRANTY CLAIMS INVOLVED MORE THAN ONE WHEEL REPLACEMENT.ALTHOUGH THE SUBJECT VEHICLES HAVE BEEN IN SERVICE FOR A LONGER PERIOD OF TIME THAN VEHICLES INVESTIGATED IN THE PREVIOUS INVESTIGATIONS OF TWO-PIECE WHEEL FRACTURE, ODI DID NOT IDENTIFY ANY ALLEGATIONS OF CRASHES, RAPID AIR LOSS EVENTS DUE TO WHEEL FRACTURES OR ALLEGATIONS OF EFFECTS ON VEHICLE CONTROL OR STABILITY, AS WERE THE CASES IN PAST INVESTIGATIONS WHERE SAFETY RECALLS WERE CONDUCTED TO REPLACE AFFECTED WHEELS.THE AGENCY AGREES THAT THE SSV IS NOT SUITABLE FOR PURSUIT OR HIGH SPEED USAGE, REDUCING THE POTENTIAL FOR CRASHES OR LOSS OF CONTROL INCIDENTS TO BE CAUSED BY THE ALLEGED DEFECT. FORD IMPLEMENTED A 'SHOT PEENING' PROCESS IN JUNE 2006 WHICH REDUCED THE WHEEL'S SURFACE STRESS AND SIGNIFICANTLY IMPROVED ITS DURABILITY, AND ODI IS UNAWARE OF ANY FAILURES OF SHOT PEENED WHEELS (SERVICE PART NUMBER 7L1Z-1015-B).FORD'S TESTING SHOWED A SLIGHTLY REDUCED DURABILITY FOR THE NON-SHOT PEENED WHEELS WHEN 'LT' INSTEAD OF FORD APPROVED 'P' METRIC TYPE TIRES ARE USED. A SAFETY-RELATED DEFECT HAS NOT BEEN IDENTIFIED AT THIS TIME AND FURTHER USE OF AGENCY RESOURCES DOES NOT APPEAR TO BE WARRANTED.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST.THE AGENCY WILL TAKE FURTHER ACTION IF WARRANTED BY FURTHER C
Additional source detail variants (2)
Wheels
FORD SPECIAL SERVICE VEHICLE (SSV) EXPEDITIONS USE A STEEL FULL FACE WHEEL DESIGN SIMILAR TO THAT INVESTIGATED IN PE03009, RQ04007, EA04034 (CROWN VICTORIA POLICE INTERCEPTOR) AND PE03026 (GM PICKUPS AND SUVS).A TOTAL OF 8,251 SSVS (2.2% OF TOTAL PRODUCTION) WERE PRODUCED WITHIN MODEL YEARS 2004-2006 AND SOLD PRIMARILY FOR USE BY STATE, FEDERAL, AND MUNICIPAL LAW ENFORCEMENT (LE) AGENCIES.FORD STIPULATES THAT THE SUBJECT VEHICLES ARE NOT SUITABLE FOR HIGH SPEED OR PURSUIT OPERATIONS AND ALSO IDENTIFIED A 2004 NATIONAL INSTITUTE FOR JUSTICE VEHICLE EVALUATION REPORT WHICH ALSO ACKNOWLEDGES THIS LIMITATION. THE FULL FACE WHEEL IS FABRICATED FROM TWO PIECES: A STAMPED OUTER WHEEL DISC AND A FORMED RIM.THE TWO PIECES, WHICH TOGETHER COMPRISE THE OUTER BEAD SEAT, ARE JOINED TOGETHER WITH A CIRCUMFERENTIAL WELD.A CYCLIC BENDING MOMENT OCCURS IN THE OUTER BEAD SEAT AREA AS THE WHEEL ROTATES, RESULTING IN FATIGUE STRESSES IN THE WELD'S HEAT AFFECTED ZONE THAT CAN LEAD TO FRACTURING (CRACKING) OF THE RIM MATERIAL.BECAUSE THE FAILURE OCCURS UNDER THE OUTBOARD TIRE BEAD, AIR LEAKAGE MAY NOT READILY OCCUR WHEN THE RIM CRACKS, DEPENDENT ON HOW WELL THE BEAD SEALS ON THE RIM.IF MULTIPLE CRACKS GROW UNDETECTED AND SUDDENLY JOIN INTO A SINGLE LARGE CRACK, THE WHEEL'S STRUCTURE CAN BECOME COMPROMISED LEADING TO RAPID AIR LOSS.A RAPID AIR LOSS, ESPECIALLY AT HIGHER SPEED, MAY LEAD TO A CRASH. FORD RESPONDED TO ODI'S JANUARY 5, 2009 INFORMATION REQUEST (IR) ON FEBRUARY 24.FORD'S RESPONSE ACKNOWLEDGES A NUMBER OF WHEEL FRACTURES ON THE SSVS.HOWEVER, BASED ON ITS ASSESSMENT OF THE PERTINENT FACTORS, IT CONCLUDES THAT THE CONDITION DOES NOT REPRESENT AN UNREASONABLE RISK TO SAFETY.THE LACK OF REPORTS OF RAPID AIR LOSS, NO ALLEGED CRASHES, AND THEIR ASSESSMENT THAT A CRACKED WHEEL CAN BE DETECTED THROUGH SLOW, REPEATED AIR LOSS OR VIBRATION, WERE THE BASES FOR FORD'S CONCLUSION.FORD DISCUSSES THE RESULTS OF A STUDY IT PERFORMED ON WHEELS RETURNED FROM LE FIELD USE, DESIGN REVISIONS IT MADE TO THE SUBJECT WHEEL, AND THE OUTCOME OF DURABILITY TESTING IT CONDUCTED ON THE OLD AND NEW WHEEL DESIGNS. THE COUNTS SHOWN ABOVE INCLUDE A DUPLICATE ODI AND FORD REPORT; THE FORD COUNTS ARE UNIQUE VEHICLES ALLEGING WHEEL FRACTURE(S).SOME WARRANTY CLAIMS INVOLVED MORE THAN ONE WHEEL REPLACEMENT.ALTHOUGH THE SUBJECT VEHICLES HAVE BEEN IN SERVICE FOR A LONGER PERIOD OF TIME THAN VEHICLES INVESTIGATED IN THE PREVIOUS INVESTIGATIONS OF TWO-PIECE WHEEL FRACTURE, ODI DID NOT IDENTIFY ANY ALLEGATIONS OF CRASHES, RAPID AIR LOSS EVENTS DUE TO WHEEL FRACTURES OR ALLEGATIONS OF EFFECTS ON VEHICLE CONTROL OR STABILITY, AS WERE THE CASES IN PAST INVESTIGATIONS WHERE SAFETY RECALLS WERE CONDUCTED TO REPLACE AFFECTED WHEELS.THE AGENCY AGREES THAT THE SSV IS NOT SUITABLE FOR PURSUIT OR HIGH SPEED USAGE, REDUCING THE POTENTIAL FOR CRASHES OR LOSS OF CONTROL INCIDENTS TO BE CAUSED BY THE ALLEGED DEFECT. FORD IMPLEMENTED A 'SHOT PEENING' PROCESS IN JUNE 2006 WHICH REDUCED THE WHEEL'S SURFACE STRESS AND SIGNIFICANTLY IMPROVED ITS DURABILITY, AND ODI IS UNAWARE OF ANY FAILURES OF SHOT PEENED WHEELS (SERVICE PART NUMBER 7L1Z-1015-B).FORD'S TESTING SHOWED A SLIGHTLY REDUCED DURABILITY FOR THE NON-SHOT PEENED WHEELS WHEN 'LT' INSTEAD OF FORD APPROVED 'P' METRIC TYPE TIRES ARE USED. A SAFETY-RELATED DEFECT HAS NOT BEEN IDENTIFIED AT THIS TIME AND FURTHER USE OF AGENCY RESOURCES DOES NOT APPEAR TO BE WARRANTED.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST.THE AGENCY WILL TAKE FURTHER ACTION IF WARRANTED BY FURTHER C
Wheels:rim
FORD SPECIAL SERVICE VEHICLE (SSV) EXPEDITIONS USE A STEEL FULL FACE WHEEL DESIGN SIMILAR TO THAT INVESTIGATED IN PE03009, RQ04007, EA04034 (CROWN VICTORIA POLICE INTERCEPTOR) AND PE03026 (GM PICKUPS AND SUVS).A TOTAL OF 8,251 SSVS (2.2% OF TOTAL PRODUCTION) WERE PRODUCED WITHIN MODEL YEARS 2004-2006 AND SOLD PRIMARILY FOR USE BY STATE, FEDERAL, AND MUNICIPAL LAW ENFORCEMENT (LE) AGENCIES.FORD STIPULATES THAT THE SUBJECT VEHICLES ARE NOT SUITABLE FOR HIGH SPEED OR PURSUIT OPERATIONS AND ALSO IDENTIFIED A 2004 NATIONAL INSTITUTE FOR JUSTICE VEHICLE EVALUATION REPORT WHICH ALSO ACKNOWLEDGES THIS LIMITATION. THE FULL FACE WHEEL IS FABRICATED FROM TWO PIECES: A STAMPED OUTER WHEEL DISC AND A FORMED RIM.THE TWO PIECES, WHICH TOGETHER COMPRISE THE OUTER BEAD SEAT, ARE JOINED TOGETHER WITH A CIRCUMFERENTIAL WELD.A CYCLIC BENDING MOMENT OCCURS IN THE OUTER BEAD SEAT AREA AS THE WHEEL ROTATES, RESULTING IN FATIGUE STRESSES IN THE WELD'S HEAT AFFECTED ZONE THAT CAN LEAD TO FRACTURING (CRACKING) OF THE RIM MATERIAL.BECAUSE THE FAILURE OCCURS UNDER THE OUTBOARD TIRE BEAD, AIR LEAKAGE MAY NOT READILY OCCUR WHEN THE RIM CRACKS, DEPENDENT ON HOW WELL THE BEAD SEALS ON THE RIM.IF MULTIPLE CRACKS GROW UNDETECTED AND SUDDENLY JOIN INTO A SINGLE LARGE CRACK, THE WHEEL'S STRUCTURE CAN BECOME COMPROMISED LEADING TO RAPID AIR LOSS.A RAPID AIR LOSS, ESPECIALLY AT HIGHER SPEED, MAY LEAD TO A CRASH. FORD RESPONDED TO ODI'S JANUARY 5, 2009 INFORMATION REQUEST (IR) ON FEBRUARY 24.FORD'S RESPONSE ACKNOWLEDGES A NUMBER OF WHEEL FRACTURES ON THE SSVS.HOWEVER, BASED ON ITS ASSESSMENT OF THE PERTINENT FACTORS, IT CONCLUDES THAT THE CONDITION DOES NOT REPRESENT AN UNREASONABLE RISK TO SAFETY.THE LACK OF REPORTS OF RAPID AIR LOSS, NO ALLEGED CRASHES, AND THEIR ASSESSMENT THAT A CRACKED WHEEL CAN BE DETECTED THROUGH SLOW, REPEATED AIR LOSS OR VIBRATION, WERE THE BASES FOR FORD'S CONCLUSION.FORD DISCUSSES THE RESULTS OF A STUDY IT PERFORMED ON WHEELS RETURNED FROM LE FIELD USE, DESIGN REVISIONS IT MADE TO THE SUBJECT WHEEL, AND THE OUTCOME OF DURABILITY TESTING IT CONDUCTED ON THE OLD AND NEW WHEEL DESIGNS. THE COUNTS SHOWN ABOVE INCLUDE A DUPLICATE ODI AND FORD REPORT; THE FORD COUNTS ARE UNIQUE VEHICLES ALLEGING WHEEL FRACTURE(S).SOME WARRANTY CLAIMS INVOLVED MORE THAN ONE WHEEL REPLACEMENT.ALTHOUGH THE SUBJECT VEHICLES HAVE BEEN IN SERVICE FOR A LONGER PERIOD OF TIME THAN VEHICLES INVESTIGATED IN THE PREVIOUS INVESTIGATIONS OF TWO-PIECE WHEEL FRACTURE, ODI DID NOT IDENTIFY ANY ALLEGATIONS OF CRASHES, RAPID AIR LOSS EVENTS DUE TO WHEEL FRACTURES OR ALLEGATIONS OF EFFECTS ON VEHICLE CONTROL OR STABILITY, AS WERE THE CASES IN PAST INVESTIGATIONS WHERE SAFETY RECALLS WERE CONDUCTED TO REPLACE AFFECTED WHEELS.THE AGENCY AGREES THAT THE SSV IS NOT SUITABLE FOR PURSUIT OR HIGH SPEED USAGE, REDUCING THE POTENTIAL FOR CRASHES OR LOSS OF CONTROL INCIDENTS TO BE CAUSED BY THE ALLEGED DEFECT. FORD IMPLEMENTED A 'SHOT PEENING' PROCESS IN JUNE 2006 WHICH REDUCED THE WHEEL'S SURFACE STRESS AND SIGNIFICANTLY IMPROVED ITS DURABILITY, AND ODI IS UNAWARE OF ANY FAILURES OF SHOT PEENED WHEELS (SERVICE PART NUMBER 7L1Z-1015-B).FORD'S TESTING SHOWED A SLIGHTLY REDUCED DURABILITY FOR THE NON-SHOT PEENED WHEELS WHEN 'LT' INSTEAD OF FORD APPROVED 'P' METRIC TYPE TIRES ARE USED. A SAFETY-RELATED DEFECT HAS NOT BEEN IDENTIFIED AT THIS TIME AND FURTHER USE OF AGENCY RESOURCES DOES NOT APPEAR TO BE WARRANTED.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST.THE AGENCY WILL TAKE FURTHER ACTION IF WARRANTED BY FURTHER C
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