SEVERAL OF THE BOLTS THAT HOLD THE EXHAUST MANIFOLD ONTO THE ENGINE BLOCK HAVE POPPED OFF LEAVING THE STEM OF THE BOLT EMBEDDED IN THE ENGINE. AS A RESULT, DANGEROUS EXHAUST GASES ARE SEEPING OUT INTO THE ENGINE AREA BECAUSE THE MANIFOLD IS NO LONGER TIGHTLY ATTACHED TO THE ENGINE. IN ORDER TO FIX THE PROBLEM THE BOLTS MUST BE…
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SEVERAL OF THE BOLTS THAT HOLD THE EXHAUST MANIFOLD ONTO THE ENGINE BLOCK HAVE POPPED OFF LEAVING THE STEM OF THE BOLT EMBEDDED IN THE ENGINE. AS A RESULT, DANGEROUS EXHAUST GASES ARE SEEPING OUT INTO THE ENGINE AREA BECAUSE THE MANIFOLD IS NO LONGER TIGHTLY ATTACHED TO THE ENGINE. IN ORDER TO FIX THE PROBLEM THE BOLTS MUST BE DRILLED OUT. THIS IS A KNOWN DEFECT. THIS HAS OCCURED IN A NUMBER OF MERCURY VILLAGERS THAT USE THIS ENGINE. I HAVE PERSONALLY TALKED WITH SEVERAL MECHANICS THAT HAVE INDICATED IT IS A CONTINUAL PROPLEM WITH THIS MAKE. IT DID NOT TAKE ME LONG TO FIND OUT THAT THIS IS NOT AN ISSOLATED INSIDENT BUT ONE THAT HAS OCCURED IN MANY OF THE VILLAGER'S.
NHTSA ODI #741149
Mileage unknown · Jan 24, 2001
Engine And Engine Cooling
CRANKSHAFT BROKE AFTER BELT TIGHTENING. VEHICLE STOPPED WHEN MOVING IN TRAFFIC. HARD TO CONTROL. DANGEROUS SITUATION. *AK
NHTSA ODI #739870
Mileage unknown · Jan 23, 2001
Engine And Engine Cooling
CONSUMER HAS HAD THIS PROBLEM FOR PASSED 4 YEARS. ONLY HAPPENS WHEN IT'S COLD. INSIDE OF VEHICLE FILLS UP WITH FUMES. ONCE VEHICLE IS WARMED UP FUMES GO AWAY. DEALER SAYS THEY'VE NEVER SEEN THIS BEFORE. CONSUMER HAS AN APPOINTMENT TO INSPECT VEHICLE.*AK
NHTSA ODI #878792
Mileage unknown · Dec 28, 2000
Electrical SystemEngine And Engine CoolingEquipment
ELECTRICAL:NUMEROUS PROBLEMS WITH DOOR LOCKS ACTIVATION/WINDSHIELD SPRAYER FRONT AND REAR INOPERATIVE/INTERIOR LIGHTING CONTROLS FOR VENTILATION INOP., RADIO&CD PLAYER OPERATION INTERMITTENT AT ALL TIMES AND REPLACED RADIO BUT STILL HAD PROBLEMS GETTING POWER TO THE UNIT ON A REGULAR BASIS; HYDRAULIC BRAKES: FRONT BRAKE CALIPERS…
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ELECTRICAL:NUMEROUS PROBLEMS WITH DOOR LOCKS ACTIVATION/WINDSHIELD SPRAYER FRONT AND REAR INOPERATIVE/INTERIOR LIGHTING CONTROLS FOR VENTILATION INOP., RADIO&CD PLAYER OPERATION INTERMITTENT AT ALL TIMES AND REPLACED RADIO BUT STILL HAD PROBLEMS GETTING POWER TO THE UNIT ON A REGULAR BASIS; HYDRAULIC BRAKES: FRONT BRAKE CALIPERS NOT FUNCTIONING FULLY/REAR BRAKES MAKE GRINDING NOISES. EXHAUST SYSTEM: CHECK ENGINE LIGHT AT DIFFERENT INTERVALS DUE TO BROKEN HOSE BETWEEN EGR VALVE ASSEMBLY AND INTAKE MANIFOLD/O2 SENSOR REPLACED DUE TO TROUBLE CODES.
NHTSA ODI #738433
Mileage unknown · Dec 21, 2000
Engine And Engine Cooling
CRANKSHAFT SHEARED IN HALF . A TSB HAS BEEN ISSUED ON VEHICLE.*AK
NHTSA ODI #876898
Mileage unknown · Nov 14, 2000
Engine And Engine Cooling
FUEL TANK VENT HOSE DETERIORATED RESULTING IN SERIOUS FUEL LEAK WHEN FUEL TANK WAS FULL OR NEARLY FULL. *AK
NHTSA ODI #736303
Mileage unknown · Oct 15, 2000
Engine And Engine Cooling
PULLEY SIDE OF CRANKSHAFT BROKE OFF. STOPING ALL POWER EQUIPMENT. NEARLY KILLING ALL OCCUPANTS. OCCURED AFTER PULLING AWAY FROM STOP SIGN INTO TRAFFIC
NHTSA ODI #734363
Mileage unknown · Oct 11, 2000
Engine And Engine CoolingFuel System, GasolineVehicle Speed Control
ENGINE SHUT DOWN ON 11/21/00 WHILE TRAVELING ON INTERSTATE AT 65MPH. AUTO TOWED TO MERCURY DEALERSHIP. WE WERE TOLD WE WOULD HAVE TO REPLACE THE ENGINE AT OUR OWN EXPENSE ($4000). ONCE ENGINE WAS REPLACED, WE STARTED HAVING OTHER PROBLEMS. WE STARTED TO NOTICE THE SMELL OF GASOLINE AROUND THE VEHICLE. THE SMELL WAS ESPECIAL…
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ENGINE SHUT DOWN ON 11/21/00 WHILE TRAVELING ON INTERSTATE AT 65MPH. AUTO TOWED TO MERCURY DEALERSHIP. WE WERE TOLD WE WOULD HAVE TO REPLACE THE ENGINE AT OUR OWN EXPENSE ($4000). ONCE ENGINE WAS REPLACED, WE STARTED HAVING OTHER PROBLEMS. WE STARTED TO NOTICE THE SMELL OF GASOLINE AROUND THE VEHICLE. THE SMELL WAS ESPECIALLY BAD ON THE INSIDE WHEN WE TURNED THE HEAT ON. THE DEALERSHIP THOUGHT THEY FIXED THE PROBLEM BY TIGHTENING THE FUEL LINE CLAMPS, BUT THE ODOR RETURNED. THE GAS SMELL IS STILL PRESENT. THE NEW ENGINE WAS SLOW TO ACCELERATE. THE DEALERSHIP DID A "FIX" ON THIS BY ADJUSTING THE THROTTLE LINKAGE. THE VEHICLE STILL DOES NOT ACCELERATE AS IT DID ORIGINALLY.
NHTSA ODI #734095
Mileage unknown · Sep 15, 2000
Engine And Engine Cooling
WHEN DRIVING ON BELTWAY AT 60-65 MPH AND WITHOUT PRIOR WARNING OR INDICATION VEHICLE CUT OFF, CAUSING LOSS OF ALL POWER DUE TO CRANKSHAFT BREAKING WHICH CAUSED DAMAGE TO ENGINE. CONSUMER HAS CONTACTED DEALER. PLEASE PROVIDE ANY FURTHER DETAILS.*AK
NHTSA ODI #870618
Mileage unknown · Sep 10, 2000
Engine And Engine Cooling
CRANKSHAFT BROKE DURING HWY DRIVING. FORD SERVICE DOCUMENTATION INDICATES IT IS A KNOWN DESIGN DEFECT: "ENGINEERING DETERMINED THE CAUSE WAS THE INITIAL TENSILE FORCE SET ON THE ENGINE ACCESSORY BELTS DURING ASSEMBLY." COST TO REPAIR WAS $4000.
VEHICLE DESCRIPTION: MINIVANS. THE FUEL TANK VENT HOSE ALLOWS AIR TO VENT FROM THE FUEL TANK DURING REFUELING. CRACKS HAVE DEVELOPED IN THE VENT HOSE. IF (1) THE FUEL TANK IS OVERFILLED, NOT ALLOWING EXCESS FUEL IN THE VENT HOSE TO FLOW BACK INTO THE TANK, (2) THE VEHICLE IS DRIVEN ONLY A SHORT DISTANCE AFTER REFUELING AND, (3) THERE IS SUBSEQUENTLY SIGNIFICANT HEATING OF THE FUEL TANK, THE FUEL IN THE TANK CAN EXPAND INTO THE VENT HOSE AND LEAK FUEL.
Consequence & remedy
Consequence: FUEL LEAKAGE IN THE PRESENCE OF AN IGNITION SOURCE CAN RESULT IN A FIRE.
THE REAR LAMP SOCKET MAY NOT ILLUMINATE BECAUSE THE METAL CAN IN THE LAMP SOCKET MOVES OR SEPARATES FROM THE PLASTIC SOCKET HOUSING.
Consequence & remedy
Consequence: THIS CAN RESULT IN MALFUNCTION OF THE STOP OR REAR RUNNING LAMPS. CENTER HIGH MOUNT STOP LAMP FUNCTION IS UNAFFECTED. REAR LAMP MALFUNCTION CAN RESULT IN FOLLOWING DRIVERS NOT BEING ALERTED TO THE SUBJECT VEHICLE'S PRESENCE OR INTENDED ACTIONS, PARTICULARLY IN THE CASE IN WHICH BOTH LAMPS HAVE MALFUNCTIONED.
Remedy: DEALERS WILL INSTALL A REVISED REAR LAMP SOCKET AND WIRING ASSEMBLIES.
THE WINDSHIELDS WERE MARKED WITH A "PROTOTYPE" DESIGNATION AND NOT MARKED AS REQUIRED BY FMVSS NO. 205, "GLAZING MATERIALS."
Consequence & remedy
Consequence: CONSEQUENCE OF NON-COMPLIANCE: INCORRECT LABELING OF WINDSHIELD MAY CAUSE CONCERN OR CONFUSION ABOUT THE PROTOTYPE DESIGNATION.
Remedy: DEALERS WILL REPLACE THE WINDSHIELDS ON THE AFFECTED VANS.
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
5
EA00014 · Fuel Tank Vent Hose Leakage
Opened May 22, 2000 · Closed Jan 4, 2001
Status: closed (inferred from source dates) · Vehicle Speed Control:linkages
PERIODIC EXPOSURE TO LIQUID GASOLINE MAY RESULT IN EXTRACTION OF ANTIDEGRADANTS FROM THE SUBJECT FUEL TANK VENT HOSE.HOSES WHICH HAVE SUFFERED LOSS OF ANTIDEGRADANTS CAN DEVELOP CRACKS IN AREAS OF HIGH STRAIN.FUEL MAY SPRAY OR DRIP FROM CRACKED VENT HOSES FOLLOWING TANK FILL.STARTING AT JOB#1 1998 MY (CALIFORNIA EMISSIONS VEHICLES) AND JOB#1 1999 MY (FEDERAL EMISSIONS VEHICLES), THE SUBJECT VENT HOSE COMPOSITION CHANGED FROM NITRILE RUBBER HOSES WITH CHLOROPRENE RUBBER COVERS (NBR/CR) TO FLUOROCARBON RUBBER HOSES WITH AN OUTER LAYER BLEND OF NBR/PVC.THE CHANGES WERE MADE TO IMPROVE HYDRACARBON RESISTANCE FOR COMPLAINCE WITH NEW EVAPORATIVE EMISSIONS REGULATIONS.THE MODIFIED HOSES ARE ALSO SIGNIFICANTLY MORE RESISTANT TO DEGRADATION AND CRACKING.IN A LETTER DATED JANUARY 2, 2001, FORD NOTIFIED NHTSA THAT IT WILL CONDUCT A SAFETY RECALL CAMPAIGN TO REPLACE THE SUBJECT VENT HOSE IN AFFACTED VEHICLES.FORD WILL BEGIN NOTIFYING CUSTOMERS OF THE AFFECTED VEHICLES ON OR ABOUT THE WEEK OF FEBRUARY 12, 2001 TO RETURN THEIR VEHICLES TO DEALERS FOR REPLACEMENT OF THE FUEL TANK VENT HOSE WITH THE LATEST DESIGN LEVER PART.
PE99077 · Fuel Tank Vent Hose Leakage
Opened Dec 28, 1999 · Closed May 22, 2000
Status: closed (inferred from source dates) · Vehicle Speed Control:linkages
There is no summary currently available
EA99015 · Fuel Rail Hose Fitting Leakage
Opened Jun 29, 1999 · Closed Apr 18, 2001
Status: closed (inferred from source dates) · Vehicle Speed Control:linkages
THE ENGINEERING ANALYSIS CLOSING REPORT COVERS 1993-1998 MERCURY VILLAGER AND NISSAN QUEST MINIVANS.THESE TWO MINIVANS SHARE A COMMON BODY PLATFORM AND POWER TRAIN.BASED ON THE LOW NUMBER OF REPORTED INCIDENTS AND THE ABSENCE OF A DEMONSTRABLE FAILURE TREND, A SAFETY-RELATED DEFECT TREND HAS NOT BEEN IDENTIFIED AT THIS TIME AND FURTHER USE OF AGENCY RESOURCES IS NOT WARRANTED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT NO SAFETY-RELATED DEFECT EXISTS.THE AGENCY RESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES. SEE ENGINEERING CLOSING REPORT EA99-015 FOR DETAILS.
PE99013 · Fuel Rail Hose Fitting Leakage
Opened Feb 9, 1999 · Closed Jun 29, 1999
Status: closed (inferred from source dates) · Vehicle Speed Control:linkages
SINCE SEPTEMBER 1998, ODI HAS RECEIVED SEVEN COMPLAINTS OF FUEL ODOR OR LEAKAGE IN 1994 THROUGH 1995 MERCURY VILLAGER VEHICLES.FOUR OF THE LEAKS HAVE BEEN TRACED TO A SHORT SECTION OF HOSE THAT CONNECTS THE FUEL SUPPLY TUBE TO THE REAR OF THE FUEL RAIL.INFORMAITON CONTAINED IN THE REPORTS INDICATE THAT THE PROBLEM MAY BE DIFFICULT TO DIAGNOSE, WITH SEVERAL OWNERS ALLEGING MULTIPLE DEALER SERVICE REPAIRS.ADVANCED COMPRESSION SET IS EVIDENT IN A HOSE REMOVED FROM THE MOST RECENT COMPLAINT VEHICLE.
EA96005 · Battery Explosions
Opened May 30, 1996 · Closed May 29, 1997
Status: closed (inferred from source dates) · Electrical System
A SAFETY-RELATED DEFECT TREND HAS NOT BEEN IDENTIFIED AT THIS TIME AND FURTHER USE OF AGENCY RESOURCES DOES NOT APPEAR TO BE WARRANTED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT NO SAFETY-RELATED DEFECT EXISTS.THE AGENCY RESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.AN ENGINEERING ANALYSIS CLOSING REPORT IS INCLUDED IN THE PUBLIC FILE.
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