NHTSA owner reports · September 18, 2026 snapshot.
What owners actually said
299 reports116,000 miles · Apr 23, 2014
EngineFuel System, GasolinePower Train
WAS DRIVING DOWN OFF RAMP LOST ALL POWER TO THE VEHICLE, NO STEERING, NO BRAKES. I HAD MY 3 CHILDREN IN THE VEHICLE WITH ME AND THANKFULLY I WAS ABLE TO COST TO THE SHOULDER UNTIL HELP ARRIVED. EXTREMELY SCARY HAD IT HAPPEN 2 MINUTES EARLIER WOULD OF BEEN OFF THE RAMP AND INTO ONCOMING TRAFFIC! THIS IS UNACCEPTABLE!! MY MECHANIC…
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WAS DRIVING DOWN OFF RAMP LOST ALL POWER TO THE VEHICLE, NO STEERING, NO BRAKES. I HAD MY 3 CHILDREN IN THE VEHICLE WITH ME AND THANKFULLY I WAS ABLE TO COST TO THE SHOULDER UNTIL HELP ARRIVED. EXTREMELY SCARY HAD IT HAPPEN 2 MINUTES EARLIER WOULD OF BEEN OFF THE RAMP AND INTO ONCOMING TRAFFIC! THIS IS UNACCEPTABLE!! MY MECHANIC SAYS IT'S THE FUEL PUMP, AND JUST THE PART IS 500 DOLLARS?!? THIS COULD OF ENDED VERY BADLY AND I HAVE HAD NOTHING BUT ISSUES WITH THIS PIECE OF JUNK. THE PAINT IS PEELING OFF, LOOKS LIKE NO PRIMER OR SEALER WAS USED IT LITERALLY IS FLAKING OFF ON THE HOOD AND REAR GATE RIGHT WHERE YOU WOULD PUT YOUR HANDS TO OPEN IT. IN THE MANUAL IN VERY SMALL PRINT IT SAYS THE OIL FROM YOUR FINGERS MAY CAUSE PAINT TO CORRODE, ARE YOU KIDDING ME??? YOUR NOT SUPPOSED TO OPEN YOUR HOOD OR TAILGATE??? RIDICULOUS!! THIS VEHICLE IN MY OPINION IS A LEMON!! *TR
NHTSA ODI #10584466
113,000 miles · Apr 23, 2014
Electrical SystemEngine
WAS DRIVING DOWN THE ROAD WHEN EXPEDITION STARTED TO LURCH AND NOT SHIFT PROPERLY. TOOK IT IN TO AUTO SHOP AND THEY DIAGNOSED THAT PISTONS 3 AND 7 WERE MISFIRING. WENT TO CHANGE SPARK PLUGS AND PLUGS BROKE OFF IN THE ENGINE. HAD TO ORDER SPECIAL TOOL TO REMOVE THEM, SECOND TIME THEY HAVE HAD TO BE REPLACED BOTH TIMES THEY HAVE B…
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WAS DRIVING DOWN THE ROAD WHEN EXPEDITION STARTED TO LURCH AND NOT SHIFT PROPERLY. TOOK IT IN TO AUTO SHOP AND THEY DIAGNOSED THAT PISTONS 3 AND 7 WERE MISFIRING. WENT TO CHANGE SPARK PLUGS AND PLUGS BROKE OFF IN THE ENGINE. HAD TO ORDER SPECIAL TOOL TO REMOVE THEM, SECOND TIME THEY HAVE HAD TO BE REPLACED BOTH TIMES THEY HAVE BROKEN OFF. COST WAS OVER 1500.00 *TR
NHTSA ODI #10584459
82,000 miles · Apr 21, 2014
Engine
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING 50 MPH, THE FAIL SAFE WARNING LAMP ILLUMINATED AS THE VEHICLE STALLED. THE VEHICLE WAS TAKEN TO THE DEALER WHERE THE TECHNICIAN DIAGNOSED THAT THE SPARK PLUGS NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED BUT THE FAILURE RECURRED. THE MANUFACTUR…
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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING 50 MPH, THE FAIL SAFE WARNING LAMP ILLUMINATED AS THE VEHICLE STALLED. THE VEHICLE WAS TAKEN TO THE DEALER WHERE THE TECHNICIAN DIAGNOSED THAT THE SPARK PLUGS NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED BUT THE FAILURE RECURRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 82,000 AND THE CURRENT MILEAGE WAS 83,000.
NHTSA ODI #10583919
110 miles · Apr 17, 2014
Power Train
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT THE OVER-DRIVE FUNCTION WOULD DISENGAGE INDEPENDENTLY. CAUSING THE VEHICLE TO DECELERATE AND THEN RETURN TO NORMAL SPEED. THE VEHICLE WAS TAKEN TO THE DEALER WHERE THE TECHNICIAN DIAGNOSED THAT THE CRUISE CONTROL WAS ALTERING THE TRANSMISSION. THE VEHICLE WAS …
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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT THE OVER-DRIVE FUNCTION WOULD DISENGAGE INDEPENDENTLY. CAUSING THE VEHICLE TO DECELERATE AND THEN RETURN TO NORMAL SPEED. THE VEHICLE WAS TAKEN TO THE DEALER WHERE THE TECHNICIAN DIAGNOSED THAT THE CRUISE CONTROL WAS ALTERING THE TRANSMISSION. THE VEHICLE WAS REPAIRED BUT THE CONTACT WAS NOT ADVISED OF THE SPECIFIC REPAIRS. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 110 AND THE CURRENT MILEAGE WAS 98,421.
NHTSA ODI #10583376
133,237 miles · Apr 3, 2014
EngineSteering
AS I WAS DRIVING MY EXPEDITION, THE TRUCK SUDDENLY SHUT COMPLETELY OFF AND I HAD TO POWER STEERING AND THEN IN THE MESSAGE CENTER IT SHOWED "ENGINE FAILSAFE MODE". I HAD TO PUT MY FLASHERS ON AND COAST TO A STOP IN THE LANE I WAS IN AND COME TO A COMPLETE STOP BEFORE I COULD RESTART MY TRUCK. I WAS UNABLE TO SWITCH LANES OR MO…
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AS I WAS DRIVING MY EXPEDITION, THE TRUCK SUDDENLY SHUT COMPLETELY OFF AND I HAD TO POWER STEERING AND THEN IN THE MESSAGE CENTER IT SHOWED "ENGINE FAILSAFE MODE". I HAD TO PUT MY FLASHERS ON AND COAST TO A STOP IN THE LANE I WAS IN AND COME TO A COMPLETE STOP BEFORE I COULD RESTART MY TRUCK. I WAS UNABLE TO SWITCH LANES OR MOVE TO A SAFER LOCATION BECAUSE I HAD NO POWER STEERING. I HAD THE SAME THING HAPPEN IN MARCH OF 2009 WHEN I WAS GOING 60 ON THE INTERSTATE IN THE MIDDLE LANE AND LOST ALL POWER AND HAD TO COAST TO A STOP IN THAT LANE WITH MY FLASHERS ON HOPING EVERYONE AROUND ME WOULD SEE I WAS HAVING CAR TROUBLE. I HAD 3 OF MY KIDS IN THE TRUCK WITH ME. IN 2009 I TOOK IT INTO THE FORD DEALERSHIP AND THEY SAID IT WAS THE THROTTLE BODY AND REPLACED IT WHICH COST ME $536.00. IN 2009 IT HAPPENED 5 TIMES BEFORE IT WAS FIXED. I TOOK THE TRUCK IN TODAY AND THEY SAID AGAIN ITS THE THROTTLE BODY AND BECAUSE IT'S BEEN 5 YEARS THE OTHER ONE IS NO LONGER UNDER WARRANTY. SO NOW I'M GETTING A NEW THROTTLE BODY PUT IN. I EMAILED FORD CORPORATE AND WAS BASICALLY TOLD THAT THERE IS NO CURRENT RECALL NOR PLANS FOR ONE SO THERE'S NOTHING THEY CAN DO FOR ME! *TR
NHTSA ODI #10577260
74,300 miles · Mar 27, 2014
EngineSteeringVehicle Speed Control
THIS IS THE SECOND INCIDENT: THE FIST WAS ABOUT 3 MONTHS AGO. I WAS DRIVING DOWN A RESIDENTIAL STREET YESTERDAY WHEN THE "FAIL SAFE MODE" INDICATOR CAME ON AND SAID ENGINE SHUTTING DOWN. CAR TURNS OFF, CANNOT STEER. VERY DANGEROUS. I WAS ON A RESIDENTIAL STREET AND WAS ABLE TO PULL OFF. TURNED THE CAR OFF FOR A FEW MINUTES A…
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THIS IS THE SECOND INCIDENT: THE FIST WAS ABOUT 3 MONTHS AGO. I WAS DRIVING DOWN A RESIDENTIAL STREET YESTERDAY WHEN THE "FAIL SAFE MODE" INDICATOR CAME ON AND SAID ENGINE SHUTTING DOWN. CAR TURNS OFF, CANNOT STEER. VERY DANGEROUS. I WAS ON A RESIDENTIAL STREET AND WAS ABLE TO PULL OFF. TURNED THE CAR OFF FOR A FEW MINUTES AND IT STARTED AND I DROVE TO WORK, BUT THE ENGINE LIGHT REMAINED ON. I TOOK IT TO AN AUTO PARTS STORE WHO RAN IT AND IT CAME UP AS THROTTLE BODY FORCES IMMEDIATE IDLE. WHICH IS EXACTLY WHAT THE 10 PAGES ON COMPLAINTS ON CARCOMPLAINTS.COM SAID IT WOULD SAY - HOWEVER INFORMATION ON THAT SITE ALSO SAID IT'S ACTUALLY THE FUEL PUMP MODULATOR, BUT THE COMPUTER DID NOT INDICATE THAT AT ALL. THERE WERE ALMOST 60 COMPLAINTS OF THE SAME SITUATIONS - WHEN I PULLED OUT INTO TRAFFIC TODAY THE CAR 'HESITATED' AND DID NOT ACCELERATE CORRECTLY. THE FIRST INCIDENT OCCURRED ON A MAJOR HIGHWAY - AND AGAIN I WAS LUCKY ENOUGH TO BE IN THE RIGHT LANE AND WAS ABLE TO PULL OVER. THIS DEFECT IS GOING TO CAUSE AN INJURY OR EVEN DEATH AND IT NEEDS TO BE RECALLED AND CORRECTED. I WILL BE CONTACTING FORD CORPORATE; BUT WITH THE RECENT INCIDENTS WITH GM I WOULD HATE TO SEE AN ACCIDENT OR FATALITY OCCUR WHEN FORD AND OTHERS ARE AWARE OF THIS PROBLEM. OBVIOUSLY I HAVE TO GET THIS FIXED, I'M HOPING MY FORD DEALER WILL WORK WITH ME, BUT I HAVE A 4 YEAR OLD SO TIME IS OF THE ESSENCE AND I'M GUESSING MONEY WILL BE TOO. REGARDLESS OF FORD'S CORPORATE RESPONSE, I WILL BE CONTACTING THE MEDIA. THIS IS A SAFETY ISSUE AND IS UNACCEPTABLE THAT FORD IS NOT TAKING RESPONSIBILITY. *TR
NHTSA ODI #10575089
84,900 miles · Mar 20, 2014
Structure
RUST IN THE CHANNELS OF THE ROOF HAS PENETRATED COMPLETELY THROUGH THE SHEET METAL. VEHICLE HAS BEEN WELL MAINTAINED AND IS OTHERWISE IN PERFECT CONDITION. *TR
NHTSA ODI #10573806
91,000 miles · Mar 3, 2014
Fuel/propulsion System
CAR JUST DIED ON HIGHWAY JUST SHUT OFF WOULD NOT RESTART. AFTER LOOKING AT IT THE FPDM WAS CORRODED AND BAD. THIS HAS BEEN A INTERRMTINT PROBLEM AND HAS ALMOST CAUSED ACCIDENTS WHEN CAR STALLS WHEN DRIVING AT INTERSECTIONS AND SUCH ALUMINUM AND STEEL DONT WORK WELL UNDER A CAR AND CORRODE VERY BADLY. *TR
NHTSA ODI #10566784
132,000 miles · Feb 28, 2014
EngineSteeringVehicle Speed Control
I WAS DRIVING AROUND 46MPH, AND IN THE MIDDLE OF DRIVING, MY TRUCK CUT OFF FOR AROUND 5 SECONDS. I ALMOST GOT BY THE TRUCK BEHIND ME. MY TRUCK KICKED BACK ON BY ITSELF, ALL WHY I WAS DRIVING. I WAS SO TERRIFIED THE TRUCK BEHIND ALMOST REAR ENDED ME. *TR
NHTSA ODI #10566562
96,000 miles · Feb 7, 2014
Vehicle Speed Control
TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING 65 MPH, THE FAIL SAFE MODE WARNING LIGHT ILLUMINATED AS THE VEHICLE INDEPENDENTLY DECELERATED AND STALLED. THE VEHICLE WAS TOWED TO THE DEALER, WHO STATED THAT THE THROTTLE BODY WOULD NEED CLEANING. THE VEHICLE WAS REPAIRED BUT THE FAILURE RECURRE…
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TL* THE CONTACT OWNS A 2006 FORD EXPEDITION. THE CONTACT STATED THAT WHILE DRIVING 65 MPH, THE FAIL SAFE MODE WARNING LIGHT ILLUMINATED AS THE VEHICLE INDEPENDENTLY DECELERATED AND STALLED. THE VEHICLE WAS TOWED TO THE DEALER, WHO STATED THAT THE THROTTLE BODY WOULD NEED CLEANING. THE VEHICLE WAS REPAIRED BUT THE FAILURE RECURRED SEVERAL MONTHS LATER. THE VEHICLE WAS TAKEN BACK TO THE DEALER, WHO STATED THAT THE ENTIRE THROTTLE BODY WOULD NEED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURE WAS CONTACTED. THE APPROXIMATE FAILURE MILEAGE WAS 96,000.
NHTSA ODI #10563369
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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