2005 FORD EXPEDITION - ELECTRONIC THROTTLE PROBLEM. THIS HAS BEEN AN ON-GOING PROBLEM SINCE 2008, A VERY DANGEROUS PROBLEM. WILL THE NOTIFICATION WARNS YOU THE CAR DIES IN MID-TRAFFIC CAUSING YOU TO COAST AND THEN THE ENGINE DIES. I HAVE HAD THIS FIXED IN 2008 AND IN 2009 AND 2010 IS HAVING THE SAME ISSUE - SOMEONE WILL END U…
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2005 FORD EXPEDITION - ELECTRONIC THROTTLE PROBLEM. THIS HAS BEEN AN ON-GOING PROBLEM SINCE 2008, A VERY DANGEROUS PROBLEM. WILL THE NOTIFICATION WARNS YOU THE CAR DIES IN MID-TRAFFIC CAUSING YOU TO COAST AND THEN THE ENGINE DIES. I HAVE HAD THIS FIXED IN 2008 AND IN 2009 AND 2010 IS HAVING THE SAME ISSUE - SOMEONE WILL END UP WITH A DEATH DUE TO THIS PROBLEM. PLEASE INVESTIGATE. *TR
NHTSA ODI #10354660
70,000 miles · Apr 22, 2010
Electrical System
MY 2005 FORD EXPEDITION WILL SUDDENLY TURN OFF WHILE IN MOTION WITH NO WARNING. THERE IS NO PATTERN TO DETERMINE WHEN IT WILL TURN OFF. IN THE 6 MONTHS I HAVE OWNED THE VEHICLE, IT HAS TURNED OFF CLOSE TO A DOZEN TIMES, AT SPEEDS RANGING FROM 20 MILES AN HOUR TO FULL FREEWAY SPEED. THE ELECTRONIC THROTTLE CONTROL LIGHT TURNS ON.…
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MY 2005 FORD EXPEDITION WILL SUDDENLY TURN OFF WHILE IN MOTION WITH NO WARNING. THERE IS NO PATTERN TO DETERMINE WHEN IT WILL TURN OFF. IN THE 6 MONTHS I HAVE OWNED THE VEHICLE, IT HAS TURNED OFF CLOSE TO A DOZEN TIMES, AT SPEEDS RANGING FROM 20 MILES AN HOUR TO FULL FREEWAY SPEED. THE ELECTRONIC THROTTLE CONTROL LIGHT TURNS ON. I HAVE TAKEN IT TO A REPUTABLE MECHANIC WHO WAS UNABLE TO REPLICATE THE PROBLEM AS THE CODE REPORTED THAT THE ERROR OCCURRED WHILE THE VEHICLE WAS TURNED OFF - WHICH IS TECHNICALLY IMPOSSIBLE. RESEARCH HAS SHOWN THIS IS A COMMON PROBLEM WITH THIS VEHICLE, AND IT IS OBVIOUSLY DANGEROUS FOR A VEHICLE TO TURN OFF WHILE IT IS IN MOTION. I WOULD HOPE THIS VEHICLE IS RECALLED BEFORE INFORMATION LEAKS THAT PEOPLE HAVE DIED AS A RESULT. *TR
NHTSA ODI #10326986
45,000 miles · Apr 11, 2010
Electrical System
WHILE DRIVING MY FORD 2005 EXPEDITION THE CAR STOPS RESPONDING TO THE THROTTLE AND LOSSES ALL POWER. THE DASHBOARD WARNING SYSTEM DISPLAYS "CHECK ELECTRONIC THROTTLE CONTROL". AFTER SHUTTING THE ENGINE OFF AND WAITING SEVERAL MINUTES THE CAR CAN BE RESTARTED AND DRIVEN. WE HAVE INQUIRED ABOUT THIS ISSUE WITH NO SATISFACTION. *TR…
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WHILE DRIVING MY FORD 2005 EXPEDITION THE CAR STOPS RESPONDING TO THE THROTTLE AND LOSSES ALL POWER. THE DASHBOARD WARNING SYSTEM DISPLAYS "CHECK ELECTRONIC THROTTLE CONTROL". AFTER SHUTTING THE ENGINE OFF AND WAITING SEVERAL MINUTES THE CAR CAN BE RESTARTED AND DRIVEN. WE HAVE INQUIRED ABOUT THIS ISSUE WITH NO SATISFACTION. *TR
NHTSA ODI #10324956
64,085 miles · Feb 14, 2010
Electrical System
MY 2005 FORD EXPEDITION SUDDENLY LOST ALL POWER WHILE DRIVING IN ROSEVILLE, CA ON SATURDAY FEBRUARY 13TH 2010. MY FAMILY OF FOUR WAS IN THE CAR, AND LUCKILY, WE AVOIDED AN ACCIDENT. A "ENGINE FAIL SAFE MODE" LIGHT CAME ON, AND I HAD TO PULL ON THE SIDE OF THE ROAD. I RESTARTED MY VEHICLE WITH NO PROBLEMS. *TR
NHTSA ODI #10310262
47,000 miles · Feb 1, 2010
Electrical System
SEVERAL TIMES WHILE DRIVING MY FORD 2005 EXPEDITION THE CAR STOPS RESPONDING TO THE THROTTLE AND LOSSES ALL POWER CAUSING AN UNSAFE CONDITION IN TRAFFIC. THE DASHBOARD WARNING SYSTEM DISPLAYS "CHECK ELECTRONIC THROTTLE CONTROL". AFTER SHUTTING THE ENGINE OFF AND WAITING SEVERAL MINUTES THE CAR CAN BE RESTARTED AND DRIVEN. WE HAV…
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SEVERAL TIMES WHILE DRIVING MY FORD 2005 EXPEDITION THE CAR STOPS RESPONDING TO THE THROTTLE AND LOSSES ALL POWER CAUSING AN UNSAFE CONDITION IN TRAFFIC. THE DASHBOARD WARNING SYSTEM DISPLAYS "CHECK ELECTRONIC THROTTLE CONTROL". AFTER SHUTTING THE ENGINE OFF AND WAITING SEVERAL MINUTES THE CAR CAN BE RESTARTED AND DRIVEN. WE HAVE INQUIRED ABOUT THIS ISSUE WITH NO SATISFACTION. *TR
NHTSA ODI #10303658
57,368 miles · Jan 21, 2010
Electrical System
WHILE TRAVELING AT APPROXIMATELY 60 MPH IN MORNING RUSH HOUR ON A MAJOR HIGHWAY A MESSAGE APPEARED ON THE DISPLAY BOARD STATING CHECK ELECTRONIC THROTTLE SENSOR VEHICLE THEN IMMEDIATELY DIED AND I WAS UNABLE TO ACCELERATE. I WAS ABLE TO COAST TO THE SHOULDER ATTEMPTING TO AVOID ANY COLLISIONS. ONCE I CAME TO A STOP I PLACED THE…
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WHILE TRAVELING AT APPROXIMATELY 60 MPH IN MORNING RUSH HOUR ON A MAJOR HIGHWAY A MESSAGE APPEARED ON THE DISPLAY BOARD STATING CHECK ELECTRONIC THROTTLE SENSOR VEHICLE THEN IMMEDIATELY DIED AND I WAS UNABLE TO ACCELERATE. I WAS ABLE TO COAST TO THE SHOULDER ATTEMPTING TO AVOID ANY COLLISIONS. ONCE I CAME TO A STOP I PLACED THE VEHICLE IN PARK AND TURNED THE IGNITION OFF. AFTER A FEW MINUTES I RESTARTED THE CAR WITHOUT ANY PROBLEMS. THE MESSAGE ON THE DISPLAY SCREEN WAS NO LONGER THERE BUT THE CHECK ENGINE WAS ON. FOR THE REMAINDER OF THE DAY I HAD NO FURTHER ISSUES. THE FOLLOWING DAY AFTER WORK IT HAPPENED AGAIN IN 5:00 TRAFFIC. ONCE RETURNING HOME I BEGAN TO DO SOME RESEARCH ON THIS ISSUE. TO MY SURPRISE I AM NOT THE ONLY ONE HAVING THIS ISSUE. THERE ARE 100'S OF POST ON LINE IN MULTIPLE PLACES INQUIRING ABOUT THIS ISSUE. MY CONCERN IS THE SAFETY OF MY FAMILY AND OTHERS THAT MAY BE ON THE HIGHWAY WHEN THIS ISSUE OCCURS. WHEN THIS OCCURS YOU ARE UNABLE TO ACCELERATE. THIS COULD CAUSE SEVERE ACCIDENTS AS WELL AS DEATHS IF THIS ISSUE IS NOT ADDRESSED. *TR
NHTSA ODI #10301677
97,600 miles · Jan 4, 2010
Electrical System
WHILE DRIVING ON TWO DIFFERENT OCCASIONS A MESSAGE HAS APPEARED ON MY INSTRUMENT PANEL SAYING, "CHECK ELECTRONIC THROTTLE CONTROL." WHEN THIS HAPPENS I IMMEDIATELY LOSE MY ACCELERATION. BOTH TIMES I WAS ON A HILL AND THANK GOODNESS I DID NOT LOSE BRAKING ABILITY AS DESCRIBED BY OTHERS. WHEN YOU ARE ON A HILL IN A VEHICLE OF THIS…
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WHILE DRIVING ON TWO DIFFERENT OCCASIONS A MESSAGE HAS APPEARED ON MY INSTRUMENT PANEL SAYING, "CHECK ELECTRONIC THROTTLE CONTROL." WHEN THIS HAPPENS I IMMEDIATELY LOSE MY ACCELERATION. BOTH TIMES I WAS ON A HILL AND THANK GOODNESS I DID NOT LOSE BRAKING ABILITY AS DESCRIBED BY OTHERS. WHEN YOU ARE ON A HILL IN A VEHICLE OF THIS SIZE IT IS NEARLY IMPOSSIBLE TO MANEUVER TO A SAFE LOCATION. THE FIRST TIME THIS OCCURRED WAS NOVEMBER 27, 2009 AND AGAIN YESTERDAY, JANUARY 3, 2010. I AM ALMOST 6 MONTHS PREGNANT AND TRANSPORT 4 YOUNG CHILDREN TO AND FROM SCHOOL. AFTER RESEARCHING THIS PROBLEM ONLINE, I HAVE DISCOVERED THAT THIS IS A VERY COMMON PROBLEM ON THE 2005 FORD EXPEDITION. I AM VERY AFRAID THAT SOMEONE IS GOING TO BE SERIOUSLY INJURED OR KILLED BY THIS FAILURE. I HAVE READ MANY REPORTS ON HERE DATING BACK MORE THAN A YEAR AND I AM CURIOUS AS TO WHAT IT TAKES TO HAVE THIS RECALLED. HEAVEN FORBID SOMEONE LOSES THEIR LIFE. *TR
NHTSA ODI #10297955
78,000 miles · Jul 12, 2009
Electrical System
ELECTRIC THROTTLE CONTROL WENT OUT WHILE DRIVING AST 60 MPH ALSO IGNITION FUSE WENT OUT SO CAR WAS DEAD LEAVING ME STRANDED IN THE MIDDLE OF NO WHERE WITH 4 GIRLS IN THE CAR. THE ENGINE LITERALLY STOPPED WHILE I WAS DRIVING AT 60 MPH. COULD HAVE BEEN VERY DANGEROUS IF ON A CROWDED INTERSTATE. *TR
NHTSA ODI #10276440
89,923 miles · Jun 17, 2009
Electrical System
WHILE DRIVING OUR 2005 FORD EXPEDITION THE "CHECK THROTTLE" LIGHT CAME ON. THE CAR IMMEDIATELY QUIT RUNNING AND FORTUNATELY I WAS ABLE TO COAST TO A STOP. WE CALLED OUR FORD DEALERSHIP AND WAS TOLD THEY THOUGHT A RECALL HAD BEEN ISSUED FOR THIS PROBLEM. WE TOOK THE CAR TO THE FORD DEALERSHIP AND WAS TOLD THEN THAT THEY COULD N…
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WHILE DRIVING OUR 2005 FORD EXPEDITION THE "CHECK THROTTLE" LIGHT CAME ON. THE CAR IMMEDIATELY QUIT RUNNING AND FORTUNATELY I WAS ABLE TO COAST TO A STOP. WE CALLED OUR FORD DEALERSHIP AND WAS TOLD THEY THOUGHT A RECALL HAD BEEN ISSUED FOR THIS PROBLEM. WE TOOK THE CAR TO THE FORD DEALERSHIP AND WAS TOLD THEN THAT THEY COULD NOT FIND A RECALL FOR THIS PROBLEM. IT COSTS US $626.37. WE HAVE SINCE LEARNED THAT THERE HAVE BEEN NUMEROUS COMPLAINTS ABOUT THIS SAME PROBLEM ON 2005 FORD EXPEDITIONS. WAS TOLD WHEN WE CALLED FORD HEADQUARTERS THAT WE NEEDED TO FILE A COMPLAINT. *TR
NHTSA ODI #10274123
64,843 miles · Apr 27, 2009
Electrical System
THIS IS THE 5TH TIME THIS PARTICULAR MALFUNCTION HAS OCCURRED WITHIN A 4 MONTH PERIOD. WHILE CRUISING AT LOW SPEED (5-15 MPH) IN STOP AND GO TRAFFIC, THE ENGINE LIGHT ILLUMINATES AND THE VEHICLE SHUTS DOWN. WITH THE VEHICLE ENGINE OFF THERE ISN'T ANY POWER STEERING AND DRIVER MUST MANEUVER SAFELY TO THE SIDE OF THE ROAD AND COME…
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THIS IS THE 5TH TIME THIS PARTICULAR MALFUNCTION HAS OCCURRED WITHIN A 4 MONTH PERIOD. WHILE CRUISING AT LOW SPEED (5-15 MPH) IN STOP AND GO TRAFFIC, THE ENGINE LIGHT ILLUMINATES AND THE VEHICLE SHUTS DOWN. WITH THE VEHICLE ENGINE OFF THERE ISN'T ANY POWER STEERING AND DRIVER MUST MANEUVER SAFELY TO THE SIDE OF THE ROAD AND COME TO A COMPLETE STOP, PLACE VEHICLE IN PARK AND RESTART THE ENGINE. THE ERROR MESSAGE IS ABOUT THE THROTTLE CONTROL AND THE VEHICLE IS ONLY 4 YEARS OLD WITH 64,000 MILES. THIS IS A SAFETY CONCERN ESPECIALLY AT HIGH RATES OF SPEED AND THE PART IS NOT COVERED BY THE VEHICLE WARRANTY. I WENT TO THE FORD DEALER WHERE WE PURCHASED VEHICLE AND WAS CHARGED $684.00 TO REPLACE THE ELECTRONIC THROTTLE CONTROL. THAT'S WHEN I LEARNED THAT THIS MALFUNCTION HAS RECENTLY BEEN OCCURRING ON SEVERAL 2005 FORD EXPEDITION VEHICLES IN THE LAST 6 MONTHS. APPARENTLY, THERE IS NO FORD RECALL FOR THIS PART AND IT IS A TRUE SAFETY CONCERN FOR ALL FORD EXPEDITION OWNERS. *TR
NHTSA ODI #10266993
Official recalls
0
No recalls in this snapshot.
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
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