2005 Ford Cvpi problems

What is wrong

On certain police vehicles equipped with steel wheels, some of the wheels may develop cracks in the rim near the weld line that connects the rim to the disk.

Risk

The cracks can ultimately result in rapid air loss from the tire and could affect vehicle control, increasing the risk of a crash.

Remedy

Dealers will inspect and replace the four road wheels and spare wheel based on the wheel part number. The recall began on march 15, 2007. Owners should contact ford at 1‑800‑343‑5338.

Recall number 07V079000 · Recall details

What is wrong

On certain police interceptors (cvpi) and commercial heavy duty (taxi) vehicles, at extremely high operating temperatures, the sound insulating panel, located under the vehicle positioned between the exhaust system and the underbody, could sag and possibly contact the surface of the catalytic converter.

Risk

If this occurs, the insulator might experience charring of the outer layer, burning odor, or smoke which may ultimately result in a fire.

Remedy

Dealers will remove the existing dash insulator and install a revised design insulator pad free of charge. The recall began on june 3, 2005. Owners may contact ford at 1‑800‑392‑3673.

Recall number 05V206000 · Recall details

In its recall notice dated August 26, 2013, Ford Motor Company (Ford) notified the federal safety agency of a safety defect condition that may result in loss of steering in approximately 355,000 model year (MY) 2005 through 2011 Ford Crown Victoria and Mercury Grand Marquis vehicles built at the St. Thomas Assembly Plant, MY 2005 through 2007 Lincoln Town Car vehicles built at the Wixom Assembly Plant, and certain MY 2008 through 2011 Lincoln Town Car vehicles built at the St. Thomas Assembly Plant and that are currently registered or were originally sold in Connecticut, Delaware, the District of Columbia, Illinois, Indiana, Iowa, Kentucky, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, Virginia, West Virginia, or Wisconsin (the federal safety agency Recall 13V‑385, Ford Recall 13S08).Ford's recall addresses a corrosion related defect in the lower intermediate shaft that may result in separation of the steering column lower bearing and loss of steering control.Ford's recall will remedy the defect condition by instructing dealers to replace the lower intermediate shaft and to inspect and repair the upper intermediate shaft and steering column lower bearing as necessary.A retaining clip will be installed if the lower bearing has separated.Ford's investigation of steering column separations in the subject vehicles identified a defect condition in the lower intermediate shaft that could result in separation of the column lower bearing.According to Ford's August 26th defect report, severe corrosion of the lower intermediate shaft may cause the lower intermediate shaft swing link joint(s) to stiffen or seize.Ford determined that forces acting on the upper intermediate shaft because of seized swing links may eventually cause the upper intermediate shaft to collapse, which may result in separation of the column lower bearing and loss of steering control.Analysis of ODI complaints and Ford complaints and warranty identified 22 incidents of steering separation (12 complaints and 10 non-duplicative warranty claims) that may be related to the lower intermediate shaft defect condition.All 22 incidents involved vehicles in the recall region, where 419,210 or roughly half (52%), of the subject vehicles were sold.Ford's investigation also determined that column lower bearing separation may occur in vehicles that experienced upper intermediate shaft collapse in prior frontal impact collisions if the shaft was not properly diagnosed and repaired.Ford identified 13 steering separation incidents outside the recall region (6 complaints and 7 non-duplicative warranty claims) where 386,003 of the subject vehicles were sold.Ford did not find evidence of the lower intermediate shaft corrosion issue in these vehicles.Six of the vehicles had known prior collisions and the histories of the remaining 7 were unknown.To address concerns with possible steering separations in vehicles outside the region for safety recall 13V‑385, Ford is conducting a Regional Program (13R01) to inspect and repair the steering assemblies of those vehicles as necessary.The lower intermediate shaft will be replaced only if it fails the inspection, the upper intermediate shaft will be repaired if it fails a Ford-specified measurement test.In the event the steering column lower bearings are found out of position, they will be re-seated and secured with a retaining clip.Based on Ford's field actions, this investigation is closed.The VOQs cited above can be viewed at www-odi.the federal safety agency.dot.gov/owners/Searchreference under the following identification numbers: 10505992, 10479893, 10477192, 10475950, 10474596

EA13004

Fracture (cracking) of the subject vehicle (sv) wheel, which was previously investigated under preliminary evaluation pe03-009 (safety recall 03v‑279), occurs in the model year (my) 2003 to 2005 police interceptor vehicles only; civilian specification and other my vehicles are unaffected by this condition.for the affected subject wheels, a fatigue crack occurs in the heat affected zone of the rim material adjacent to the circumferential weld that attaches the rim to the outboard wheel disc.the crack initiates under the outboard tire bead near the heel (where air leakage cannot be assured) and subsequently grows circumferentially through cyclic bending as the wheels rolls.although the vast majority of rim cracks either presented no symptoms or were detected safely via recurring slow air leakage, odi identified 6 incidents where rapid air leakage leading to a full or partial deflation of the tire was alleged.for these wheels, evidence indicated that multiple cracks had formed in different areas of the rim and subsequently grown together.two of the incidents resulted in a crash, one during a high speed pursuit.although the minority of cases, ford?s assessments of field return wheels showed that multiple cracks exist in approximately 17 percent of the cracked wheels replaced under a ford extended warranty program.in a wheel with multiple cracks, as the area between the cracks is reduced by growth a high stress condition (such as would occur in an aggressive vehicle maneuver during a high-speed pursuit) may cause the cracks to join together rapidly.if the cracks are of sufficient size, the structural integrity of the rim may be compromised resulting in rapid air loss and rim deformation.for police vehicles used at high speed, rapid deflation and loss of rim structural integrity affects vehicle control and may increase the risk of a crash.fatigue is the fundamental fracture mechanism; therefore, wheel fracture can be expected to occur (and at an increased incidence level) as long as the affected wheels remain in service.in december 2004 (within my 2005 sv production) ford introduced a shot peen process into the manufacture of sv wheels.shot peen wheels, which are identified by unique part number stampings, have not exhibited fracture in police service to date.under 07v‑079, ford will inspect svs registered for police use and replace earlier design level wheels with shot peen wheels.police agencies should be advised that my 2005 vehicles built after december 2004 are not within the scope of this recall (since they were originally manufactured with shot peen wheels).agencies should be diligent in ensuring that non-shot peen wheels are removed from out-of-scope vehicles or other wheel supply inventories.

EA04034

During a september 23, 2004 meeting and in subsequent discussions in november, ford advised the office of defects investigation (odi) of their plans to introduce an improved steel wheel for manufacturing and service component use on the subject vehicles, indicating this would occur in december 2004.the new wheel design incorporates an additional manufacturing process (shot peening) which lowers tensile stress in the surface layer of the rim material adjacent to the circumferential weld. Theoretically this should improve rim durability by reducing fatigue crack initiation sites.indications from ford?s accelerated testing methods show an improvement in the performance of the new wheel.in addition to prior safety recall 03v279 and service action (sa) 03m03, ford will announce a new extended warranty sa for vehicles built prior to december 2004 that suffer rim fractures in service.the new wheel design will be used as a remedy.ford advises that a sa is sufficient for addressing future wheel failures (including recall 03v279 remedy wheel failures) because: 1) failure rates are low based on ford?s analysis, and 2) driver warnings (repetitive slow air loss, and or steering wheel vibration) allow early and safe detection of cracked wheels.odi has received 25 vehicle owner questionnaire (voq) reports (involving 22 vehicles) which allege a rim fracture of one or more steel wheels.about half the reports involve vehicles built with the remedy wheel used for recall 03v279, and most of the remaining vehicles were subject to the recall.the process of identifying pertinent ford complaints is made difficult by ford?s prior recall and warranty program activities.the manufacturer complaint and warranty counts, which primarily involve failures of recall 03v279 remedy wheels, are based on analysis conducted to date and are considered to be conservative.further investigation is required, thus odi is upgrading this investigation to an engineering analysis (ea).during the ea, pertinent failure reports and consequences will be identified and reviewed.odi and ford will discuss details for conducting an audit analysis of failed wheels replaced under the new sa.additionally, odi is awaiting ford?s lab analysis of two wheels which were the subject of voq reports, one of which was involved in the noted crash event.a determination will be made as to whether ford?s service action is sufficient for addressing ongoing rim fractures.

RQ04007