2006 Ford Expedition

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

the service engine light continues to turn on. the timing belt continues to fail and has already been replaced once. the camshaft on both sides have been replaced. the solenoids have also been replaced and the diagnostics codes still pop up (p0022) (p0021) are just some that i can remember. the engine does not have enough power on the driver side and throws the timing belt off which causes the loud rattle coming from the engine. when reaching the speed of 40-45 mph the truck begins to shake. recently in november 2023, when fueling up with gas , the truck began to shake and not respond. when accelerating, the truck takes off very slowly and the gears dont kick in on time. when the gas light comes on , the truck begins to function well. but as soon as i put gas again. it feels like the truck is going to fall apart. the driver door gets stuck when trying to open from the inside. the back door on the left does not open from the outside. the gear handle can be moved up and down while the truck is not turned on. please help!!

NHTSA ID

11564296

Incident

Jan 8, 2024

The contact owns a 2006 Ford Expedition. The contact stated that while driving 35 MPH, the contact stated that there were exhaust fumes inside the vehicle. The engine warning light was illuminated. The vehicle was diagnosed by an independent mechanic and confirmed the failure was a defective charcoal canister for the evac system. The vehicle had not been repaired. The manufacturer was made aware of the failure however, the part was not available. The failure mileage was approximately 70,000.

NHTSA ID

11539771

Incident

Oct 9, 2022

Mileage

70,000 mi

The contact owns a 2006 Ford Expedition. The contact stated that while driving at a low rate of speed, the vehicle would independently accelerate upon depression of the accelerator pedal without warning. During a recent failure, the contact crashed into a fence as part of the fence had become wedged underneath the vehicle. After placing the vehicle into park and exiting the vehicle, the wheels continued to move. The air bags did not deploy upon impact. Despite minor soreness to his neck, no medial attention was required. A police report was not filed. Despite the failure, the contact managed to restart the vehicle and safely to his destination. The fence sustained severe damage as a result of the failure. The dealer nor the manufacturer had yet to be notified of the failure. The vehicle had yet to be diagnosed or repaired. The failure mileage was approximately 220,000.

NHTSA ID

11518263

Incident

Apr 20, 2023

Mileage

222,000 mi

The contact owns a 2006 Ford Expedition. The contact stated while driving 55 MPH, the vehicle was driving sluggishly. The contact stated that the check engine warning light was illuminated. The vehicle was not drivable. The contact towed the vehicle to an independent mechanic and was informed that the ignition coil, the throttle body sensor (TBS) sensor, and the timing chain needed to be replaced. The vehicle was not repaired. The vehicle was not diagnosed or repaired at the dealer. A dealer was not contacted. The manufacturer had been informed of the failure. The contact stated on another occasion the vehicle failed to start. The vehicle was not drivable. The failure mileage was approximately 130,000.

NHTSA ID

11490173

Incident

Feb 1, 2020

Mileage

130,000 mi

While driving yesterday i heard a pop. The 4th coil pack literally blew out from its spot. I have now had 3 coil packs blow out at random causing the holes that the bolt straps the coil pack to the spark plug to strip out. I have a transmission leak that will not stop and I've taken it in multiple times for repairs and it still is leaking. Since getting this vehicle i noticed at the electrical issue where everything including my headlights will shut off and then pop back on while I'm driving. My seat belt will not open so i can buckle and I'm now getting frustrated because I've spent a lot of money on this only to realize has had the same issue with previous owners and they for some reason were too embarrassed to report it but I'm not and I'm sick of dumping money into this damb thing!

NHTSA ID

11443423

Incident

Dec 10, 2021

UPON RECEIVING TUNE UP THE SPARK PLUGS BROKE APART.AFTER GETTING THEM OUT CYL#1 WOULD NOT HOLD SPARK PLUG,CAUSED ME TO SPEND MORE MONEY TO GET PROBLEM FIXED.BUT THE SHOPS WILL NOT GUARANTEE THE WORK THAT IS NEEDED.THEY ALL SAID IT WAS A FACTORY ISSUE.THE TRUCK WAS STATIONARY AS WELL.

NHTSA ID

11300564

Incident

Oct 1, 2019

TL* THE CONTACT CALLED ON BEHALF OF THE OWNER OF A 2006 FORD EXPEDITION. WHEN THE VEHICLE WAS STARTED, THERE WAS AN ODOR OF ANTIFREEZE IN THE VEHICLE. ADDITIONALLY, THE TEMPERATURE GAUGE AND CYLINDER HEAD TEMPERATURE SWITCH BECAME INOPERABLE. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO DIAGNOSED THAT THE INTAKE MANIFOLD AND CYLINDER HEAD TEMPERATURE SWITCH NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE DEALER WAS NOT CONTACTED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 245,000.

NHTSA ID

11232007

Incident

Jul 1, 2019

Mileage

245,000 mi

TRAVELING ON OLD ADOBE RD IN PETALUMA, CA AT APPROX. 25-30 MPH, WENT OVER INCLINE AND SAW TRAFFIC WAS STOPPED. PRESSED HARD ON BRAKE PEDAL AND VEHICLE SLOWED BUT DID NOT STOP. RESULTED IN A 3 CAR ACCIDENT

NHTSA ID

11207898

Incident

May 14, 2019

This article supersedes TSB 22-2219 to update the Parts List and Service Procedure to clarify applicable steps by vehicle application. Some 2003-2020 Expedition/Navigator and 2006-2020 F-150 (non-Raptor) vehicles equipped with 4WD may exhibit grinding/clicking/ratcheting noise from the front wheel area. This may be due to partial engagement of the integrated wheel ends (IWE). To correct this condition, follow the Service Procedure to remove and cap the vacuum supply line or to reprogram the transfer case control module (TCCM) and replace any worn vacuum and/or IWE components.

For 2000-2024 Ford and Lincoln vehicles, swapping a module from a vehicle for diagnosis purposes is likely to cause errors and is not recommended. It is also not recommended to order a replacement module using a vehicle identification number (VIN) from a different vehicle. Most modules on these affected vehicles are VIN/vehicle specific and hardware variations between modules do exist. Swapping a module from a vehicle or ordering a module using a different vehicle/VIN can cause ineffective repairs and additional vehicle down time. Make sure all appropriate Workshop Manual (WSM) procedures are followed when diagnosing the condition prior to all module replacements and only order modules using the correct VIN.

Some 2003-2020 Expedition/Navigator and 2006-2020 F-150 (non-Raptor) vehicles equipped with 4WD may exhibit grinding/clicking/ratcheting noise from the front wheel area. This may be due to partial engagement of the integrated wheel ends (IWE). To correct this condition, follow the Service Procedure to remove and cap the vacuum supply line or to reprogram the transfer case control module (TCCM) and replace any worn vacuum and/or IWE components.

Some 2003-2020 Expedition/Navigator and 2006-2020 F-150 vehicles equipped with TOD transfer cases may exhibit grinding/clicking/ratcheting noise from the front wheel area. This may be due to partial engagement of the integrated wheel ends (IWE). To correct this condition, follow the Service Procedure steps to remove and cap the vacuum supply line.

This article supersedes TSB 19-2026 to update the vehicle model years affected. Some 2000 and newer Ford/Lincoln/Mercury vehicles equipped with aluminum body panels may exhibit corrosion concerns appearing as bubbled and/or peeling paint with or without accompanying white dust. Panel replacement is recommended.

Some 2000 and newer Ford, Lincoln and Mercury vehicles equipped with aluminum body panels may exhibit corrosion concerns appearing as bubbled and/or peeling paint with or without accompanying white dust. Panel replacement is recommended. Follow the Service Procedure steps to correct the condition