NHTSA owner reports · September 18, 2026 snapshot.
What owners actually said
299 reports92,000 miles · Mar 24, 2015
EngineSteeringVehicle Speed Control
I WAS DRIVING ABOUT 25-30MPH AND MAKING A LEFT TURN. THE VEHICLE SUDDENLY SHUT OFF. I HAD NO POWER STEERING OR ANYTHING. IT WAS TOTALLY OFF AND STOPPED IN THE MIDDLE OF THE ROAD. IF A CAR HAD BEEN COMING IT WOULD HAVE HIT US. I WAS ABLE TO TURN OFF THE KEY, PUT IT IN PARK AND START IT UP AND PULL OFF THE ROAD. I DECIDED TO CAREF…
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I WAS DRIVING ABOUT 25-30MPH AND MAKING A LEFT TURN. THE VEHICLE SUDDENLY SHUT OFF. I HAD NO POWER STEERING OR ANYTHING. IT WAS TOTALLY OFF AND STOPPED IN THE MIDDLE OF THE ROAD. IF A CAR HAD BEEN COMING IT WOULD HAVE HIT US. I WAS ABLE TO TURN OFF THE KEY, PUT IT IN PARK AND START IT UP AND PULL OFF THE ROAD. I DECIDED TO CAREFULLY TRY TO GET HOME. ON THE WAY HOME I WAS STOPPED AT A RED LIGHT AND IT SHUT OFF AGAIN, NO WARNING. I WAS BLOCKING TRAFFIC. I WAS AGAIN ABLE TO TURN OFF THE KEY, PUT IT IN PARK, AND START IT UP. I MADE IT HOME A SHORT DISTANCE. THIS IS VERY DANGEROUS AND SOMEONE COULD GET KILLED ON A HIGHWAY BY A CAR RANDOMLY SHUTTING OFF AND BECOMING UNSTEERABLE. *TR
NHTSA ODI #10701287
90,000 miles · Feb 24, 2015
EngineSteering
WAS DRIVING ABOUT 35 MPH WHEN ENGINE FAIL SAFE MODE CAME ON AND TRUCK JUST SHUT OFF. THIS HAPPENED 4 TIMES BETWEEN LOCATION AND HOME. ALMOST GOT REARENDED WHEN IT HAPPENED. *JS
NHTSA ODI #10690292
144,000 miles · Jan 28, 2015
Air BagsVisibility/wiperCrashInjury
IT WAS SNOWING ON MY WAY TO AN APPOINTMENT AND MY WIPERS STOPPED WORKING. I COULDN'T SEE OUT OF THE WINDOWS AND ANOTHER VEHICLE HIT THE FRONT END OF MY 2006 FORD EXPEDITION. ALSO THE OTHER DRIVERS AIRBAGS DEPLOYED BUT MINE DID NOT. MY TRUCK WAS TOTALED. I SPENT THE NIGHT IN THE HOSPITAL WITH BACK INJURIES AND LEG INJURIES, AS WE…
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IT WAS SNOWING ON MY WAY TO AN APPOINTMENT AND MY WIPERS STOPPED WORKING. I COULDN'T SEE OUT OF THE WINDOWS AND ANOTHER VEHICLE HIT THE FRONT END OF MY 2006 FORD EXPEDITION. ALSO THE OTHER DRIVERS AIRBAGS DEPLOYED BUT MINE DID NOT. MY TRUCK WAS TOTALED. I SPENT THE NIGHT IN THE HOSPITAL WITH BACK INJURIES AND LEG INJURIES, AS WELL AS A HEAD INJURIES WHICH CAUSED ME TO TEMPORARILY LOSE MY MEMORY AND CONSCIOUSNESS. *TR
NHTSA ODI #10679376
88,000 miles · Jan 20, 2015
Engine
SUV ENTERED SAFE MODE ... ENGINE SHUDDERED, LOW POWER IN LOW RPM BANDS.. WOULD NOT ACCELERATE. HAD SPARK PLUGS REPLACED IN 2014 AT 88000 MILES. IN 2015, 115,000 MILES ENGINE DOES AGAIN WHILE DRIVING INTERSTATE PUTTING ME AT RISK ON ROAD OF COLLISION DUE TO POWER LOSS. DID NOT ENTER SAFE MODE SECOND TIME... JUST COULD NOT GET …
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SUV ENTERED SAFE MODE ... ENGINE SHUDDERED, LOW POWER IN LOW RPM BANDS.. WOULD NOT ACCELERATE. HAD SPARK PLUGS REPLACED IN 2014 AT 88000 MILES. IN 2015, 115,000 MILES ENGINE DOES AGAIN WHILE DRIVING INTERSTATE PUTTING ME AT RISK ON ROAD OF COLLISION DUE TO POWER LOSS. DID NOT ENTER SAFE MODE SECOND TIME... JUST COULD NOT GET POWER - HAD TO PUSH HARD ON GAS TO GET IT INTO LOWER GEAR/HIGHER RPMS. TOOK TO REPAIR SHOP THINKING COILS (COP) NEEDED REPLACED. TOLD ENGINE IS NO GOOD AND NEEDS FULL REPLACEMENT. A WRECK COULD OCCUR WHEN ENGINE FAILS LIKE THIS. ENGINES SHOULD NOT BE DEAD AT 115,000 MILES. I MAINTAINED ACCORDING TO MFG SUGGESTED MAINTENANCE SCHEDULE. *TR
NHTSA ODI #10676673
135,000 miles · Jan 15, 2015
Electrical System
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 20 MPH, THE VEHICLE STALLED WITHOUT WARNING. IN ADDITION, THE FAIL SAFE WARNING LIGHT ILLUMINATED. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 135,000…
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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 20 MPH, THE VEHICLE STALLED WITHOUT WARNING. IN ADDITION, THE FAIL SAFE WARNING LIGHT ILLUMINATED. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 135,000.
NHTSA ODI #10672818
99,000 miles · Jan 9, 2015
Engine
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 65 MPH, THE VEHICLE STALLED WITHOUT WARNING. THE VEHICLE RESTARTED HOWEVER, THE FAILURE RECURRED ON SEVERAL OCCASIONS. THE VEHICLE WAS TAKEN TO THE DEALER AND WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAIL…
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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 65 MPH, THE VEHICLE STALLED WITHOUT WARNING. THE VEHICLE RESTARTED HOWEVER, THE FAILURE RECURRED ON SEVERAL OCCASIONS. THE VEHICLE WAS TAKEN TO THE DEALER AND WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 99,000. THE VIN WAS UNAVAILABLE.
NHTSA ODI #10671241
Mileage unknown · Dec 31, 2014
Electrical SystemEngine
ENGINE FREQUENTLY GOES IN TO ENGINE FAILSAFE MODE. THIS HAPPENS TYPICALLY WHEN THE CAR IS BEING LIGHTLY THROTTLED SUCH AS AROUND CORNERS OR IN RUSH HOUR TRAFFIC. THE CAR RESTARTS FINE, BUT MUST BE COMPLETELY TURNED OFF, WHICH DISABLES AIRBAGS, MAKES POWER STEERING AND POWER BRAKES IMPOSSIBLE TO USE. PREVIOUSLY I HAVE CLEANED …
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ENGINE FREQUENTLY GOES IN TO ENGINE FAILSAFE MODE. THIS HAPPENS TYPICALLY WHEN THE CAR IS BEING LIGHTLY THROTTLED SUCH AS AROUND CORNERS OR IN RUSH HOUR TRAFFIC. THE CAR RESTARTS FINE, BUT MUST BE COMPLETELY TURNED OFF, WHICH DISABLES AIRBAGS, MAKES POWER STEERING AND POWER BRAKES IMPOSSIBLE TO USE. PREVIOUSLY I HAVE CLEANED THE THROTTLE BODY OF THE CAR AT THE SUGGESTION OF NUMEROUS MECHANICS, AND THIS RESOLVED THE ISSUE FOR NEARLY A YEAR. NOW THE PROBLEM IS BACK AGAIN. I'M CONCERNED FOR MY WIFE'S SAFETY. THE THROTTLE BODY NEEDS TO BE REDESIGNED AS THE THROTTLE PLATE STICKING RETURNING INVALID DATA TO THE COMPUTER SENDING THE ENGINE INTO FAILSAFE MODE. *JS
NHTSA ODI #10669324
100,000 miles · Dec 19, 2014
EnginePower Train
AS I AM DRIVING DOWN THE ROAD I LOSE POWER AND DEACCELERATE AND GO INTO FAIL SAFE MODE. THE LITTLE WRENCH LIGHT COMES ON THE DASH. THEN THE ENGINE CUTS OFF COMPLETELY. THIS HAS HAPPENED AT MULTIPLE SPEEDS. IT IS EXTREMELY DANGEROUS! ONCE I TURN THE KEY OFF I RESTART THE ENGINE AND IT MAY NOT HAPPEN AGAIN FOR A MONTH. I REPLACED …
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AS I AM DRIVING DOWN THE ROAD I LOSE POWER AND DEACCELERATE AND GO INTO FAIL SAFE MODE. THE LITTLE WRENCH LIGHT COMES ON THE DASH. THEN THE ENGINE CUTS OFF COMPLETELY. THIS HAS HAPPENED AT MULTIPLE SPEEDS. IT IS EXTREMELY DANGEROUS! ONCE I TURN THE KEY OFF I RESTART THE ENGINE AND IT MAY NOT HAPPEN AGAIN FOR A MONTH. I REPLACED THE THROTTLE POSITION SENSOR AND IT DID NOT DO THIS FOR ABOUT A YEAR, NOW IT IS STARTING AGAIN AND IT HAS HAPPENED 5 TIMES IN THE LAST 3 MONTHS. IT HAS HAPPENED AT 65MPH, 40MPH, 25MPH, 55MPH, 30 MPH. THERE IS NO PATTERN. I HAVE BEEN LUCKY THAT I HAVE BEEN ABLE TO PULL OVER TO THE SIDE OF THE ROAD OR TURN INTO A PARKING LOT EACH TIME THIS HAPPENS, IT SCARES ME! I HAVE READ MULTIPLE ACCOUNTS OF THIS HAPPENING ONLINE TO THE 2006 AND WONDER WHY IT HAS NOT BEEN RECALLED IF THERE ARE SO MANY PROBLEMS WITH IT. I HAVE TAKEN IT TO FORD TWICE AND BC THE LIGHT DOES NOT STAY ON AND IT IS NOT HAPPENING WHEN I BRING IT TO THEM THEY TELL ME THERE IS NOTHING THEY CAN DO. *TR
NHTSA ODI #10667242
54,000 miles · Oct 11, 2014
EngineVehicle Speed Control
ENGINE SHUT DOWN AT HIGHWAY SPEED. LOSS OF POWER STEERING AND POWER BRAKES. WAS ABLE TO COAST TO EMERGENCY LANE THEN RESTART CAR. HAPPENED TWO ADDITIONAL TIMES. TOOK TO SHOP WHERE THE THROTTLE BODY WAS REPLACED. NO ISSUES SINCE THEN (~ 1 YEAR AGO). SOUNDS LIKE MANUFACTURER DEFECT. THIS IS A SAFETY ISSUE. *TR
NHTSA ODI #10644023
120,000 miles · Sep 24, 2014
Engine
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT THE ELECTRONIC THROTTLE CONTROL AND THE SERVICE ENGINE WARNING INDICATORS ILLUMINATED. THE VEHICLE STALLED, BUT WAS ABLE TO BE RESTARTED AND RESUME NORMAL OPERATION. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. …
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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT THE ELECTRONIC THROTTLE CONTROL AND THE SERVICE ENGINE WARNING INDICATORS ILLUMINATED. THE VEHICLE STALLED, BUT WAS ABLE TO BE RESTARTED AND RESUME NORMAL OPERATION. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 120,000.
NHTSA ODI #10638800
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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