Ford Contour Recalls — All NHTSA Recall Campaigns

SUSPENSION

FEDERAL MOGUL IS RECALLING 6,903 AFTERMARKET BALL JOINT ASSEMBLIES SHIPPED BETWEEN NOVEMBER 9, 2007 AND MARCH 26, 2008, WHICH MAY HAVE BEEN PACKAGED WITH INCORRECT NUTS. THE PART NUMBERS PACKAGED WITH INCORRECT NUTS ARE: K7147, K7329, K8683, AND 104353. THESE PARTS WERE MADE FOR USE ON THE VARIOUS…

Risk: THE NUTS INCLUDED IN THE PACKAGING FOR THESE BALL JOINT ASSEMBLIES ARE MISSING THE INTENDED PREVAILING TORQUE (SELF-LOCKING) FEATURE. IF THE INCORRECT NUT WAS TO BECOME LOOSE, THE JOINING MEMBERS MAY…

Remedy: FEDERAL MOGUL WILL NOTIFY OWNERS AND REPLACE THE PARTS FREE OF CHARGE. THE RECALL BEGAN ON MAY 22, 2008. OWNERS CAN CONTACT FEDERAL MOGUL AT 877-489-6659.

SERVICE BRAKES, HYDRAULIC

CERTAIN AFTERMARKET BRAKE HYDRAULIC MASTER CYLINDERS SOLD AS REPLACEMENT BRAKE CYLINDERS FOR CERTAIN FORD, DAIMLERCHRYSLER, AND JEEP PASSENGER VEHICLES. THESE BRAKE CYLINDERS WERE SOLD UNDER THE BRAND NAMES OF NAPA, RAYBESTOS, AIMCO, AC DELCO, CARQUEST, BENDIX, AND WAGNER. ONLY PRODUCTS THAT WERE …

Risk: LOSS OF BRAKE FLUID CAN LEAD TO A DECREASE IN BRAKE LINE PRESSURE AND AN INCREASE IN STOPPING DISTANCE, WHICH CAN RESULT IN A VEHICLE CRASH.

Remedy: AFFINIA (BRAKE PARTS, INC.) WILL REPLACE THE SUBJECT BRAKE HYDRAULIC MASTER CYLINDERS FREE OF CHARGE. THE RECALL BEGAN ON MARCH 20, 2006. OWNERS CAN CONTACT AFFINA GROUP CUSTOMER SERVICE AT 1-800-32…

VISIBILITY:DEFROSTER/DEFOGGER/HVAC SYSTEM:WINDSHIELD:ELECTRICAL HEATING ELEMENT

THIS IS NOT A SAFETY RECALL IN ACCORDANCE WITH THE SAFETY ACT. HOWEVER, IT IS DEEMED A SAFETY IMPROVEMENT CAMPAIGN BY THE AGENCY. VEHICLE DESCRIPTION: 1995-1997 FORD CONTOUR AND MERCURY MYSTIQUE VEHICLES. THE HEATER BLOWER RESISTOR COULD OVERHEAT CAUSING THE ATTACHED ELECTRICAL CONNECTOR TO ME…

Risk: THIS COULD CREATE THE POTENTIAL FOR A FIRE.

Remedy: FORD WILL PROVIDE ADDITIONAL WARRANTY COVERAGE FOR THE HEATER BLOWER SWITCH FOR 10 YEARS FROM ORIGINAL DATE OF SALE OF THE VEHICLE OR 150,000 MILES, WHICHEVER COMES FIRST. DEALERS WILL INSTALL A NEW …

ELECTRICAL SYSTEM

ON CERTAIN MY 1996-1998 PASSENGER VEHICLES BUILT AT THE KANSAS CITY, CUAUTITLAN ASSEMBLY PLANTS OR ON MY 1999 PASSENGER VEHCLES BUILT AT THE AUTOMOTIVE ALLIANCE INTERNATIONAL ASSEMBLY PLANTS, THE ROUGH SURFACE OF THE HEATER BLOWER RESISTOR'S STAINLESS STEEL BLADES CAN DAMAGE THE COPPER SURFACE OF …

Risk: THE OPEN CIRCUIT COULD LEAD TO ELECTRICAL ARCING THAT COULD MELT THE CONNECTOR HOUSING MATERIAL CREASING THE POTENTIAL FOR A FIRE.

Remedy: DEALERS WILL INSTALL A NEW HEATER BLOWER RESISTOR AND A NEW WIRE JUMPER HARNESS. OWNER NOTIFICATION BEGAN AUGUST 29, 2001. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON S…

SUSPENSION:FRONT:SPRINGS:COIL SPRINGS

THIS IS NOT A SAFETY RECALL IN ACCORDANCE WITH THE SAFETY ACT. HOWEVER, IT IS DEEMED A SAFETY IMPROVEMENT CAMPAIGN BY THE AGENCY. VEHICLE DESCRIPTION: 1998 FORD CONTOUR/MERCURY MYSTIQUE PASSENGER VEHICLES BUILT AT THE KANSAS CITY ASSEMBLY PLANT. THE FRONT COIL SPRINGS COULD POTENTIALLY FRACTURE…

Risk: SOME TIRES HAVE DEFLATED DUE TO CONTACT WITH A BROKEN SPRING.

Remedy: FORD IS EXTENDING THE WARRANTY FOR FRONT COIL SPRING REPLACEMENT FOR THE FRONT COIL SPRINGS FOR 10 YEARS FROM ORIGINAL DATE OF SALE OF A VEHICLE OR 150,000 MILES, WHICHEVER COMES FIRST.

SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS

VEHICLE DESCRIPTION: PASSENGER VEHICLES NOT EQUIPPED WITH THE ANTI-LOCK BRAKING SYSTEM (ABS). A PRESSURE CONSCIOUS REDUCING VALVE (PCRV) IN THE REAR BRAKES MAY BE SUBJECT TO CORROSION AND RESULT IN MALFUNCTION, WHEN OPERATED IN AREAS THAT USE SALT COMPOUNDS ON THE ROADWAY FOR DE-ICING OR DUST CONT…

Risk: IF BOTH PCRV'S MALFUNCTION, VEHICLE HANDLING COULD BE ADVERSELY AFFECTED DURING BRAKING AS A RESULT OF THE REAR WHEELS LOCKING, INCREASING THE RISK OF A CRASH.

Remedy: DEALERS WILL INSTALL IMPROVED PCRV'S IN THE REAR BRAKE SYSTEM. THIS RECALL WAS EXPANDED IN SEPTEMBER 2000 TO INCLUDE 1999 AND 2000 FORD CONTOUR, MERCURY MYSTIQUE AND COUGAR VEHICLES.

ENGINE AND ENGINE COOLING

VEHICLE DESCRIPTION: 1995 PASSENGER VEHICLES EQUIPPED WITH THE 2.0L AND 2.5L ENGINES, AND 1996 VEHICLES EQUIPPED WITH 2.5L ENGINES. TIGHTENING OF THE ENGINE COOLING FAN MOTOR BEARINGS, UP TO AND INCLUDING MOTOR STALL, CAN RESULT IN INCREASED MOTOR TORQUE AND HIGHER THAN NORMAL MOTOR CURRENT AND AC…

Risk: OVERHEATING OF THE COOLING FAN MOTOR DUE TO EXCESSIVE CURRENT CAN RESULT IN SMOKE AND ODORS FROM BEARING GREASE, INSULATION AND OTHER INTERNAL MOTOR COMPONENTS. IF ELECTRICAL CURRENT CONTINUES TO BE …

Remedy: DEALERS WILL INSTALL A POSITIVE TEMPERATURE COEFFICIENT DEVICE IN-LINE WITH EACH FAN MOTOR. FORD WILL ALSO EXTEND THE WARRANTY ON THE ENGINE COOLING FAN ASSEMBLY TO A TOTAL OF 8 YEARS OF SERVICE OR 1…

AIR BAGS:FRONTAL

THE PASSENGER SIDE AIR BAG HAS AN INFLATOR BODY THAT CRACKED DURING FORMING OF THE CURL THAT RETAINS THE IGNITER PLUG IN THE END OF THE INFLATOR. ALSO THE IGNITER END CAP CAN SEPARATE FROM THE INFLATOR.

Risk: THE PASSENGER SIDE AIR BAG MAY NOT INFLATE PROPERLY RESULTING IN REDUCED OCCUPANT PROTECTION IN A VEHICLE ACCIDENT. IF THE IGNITER END CAP SEPARATES IN A FRONTAL COLLISION, HOT GASES CAN BE RELEASED A…

Remedy: DEALERS WILL REMOVE AND REPLACE THE PASSENGER SIDE AIR BAG MODULE.

SUSPENSION:FRONT:SPRINGS:COIL SPRINGS

VEHICLE DESCRIPTION: PASSENGER VEHICLES BUILT AT THE KANSAS CITY ASSEMBLY PLANT AND ORIGINALLY SOLD IN OR CURRENTLY REGISTERED IN THE STATES OF CONNECTICUT, DELAWARE, ILLINOIS, INDIANA, IOWA, MAINE, MARYLAND, MASSACHUSETTS, MICHIGAN, MINNESOTA, MISSOURI, NEW HAMPSHIRE, NEW JERSEY, NEW YORK, OHIO, P…

Risk: SOME TIRES HAVE DEFLATED DUE TO CONTACT WITH A BROKEN SPRING.

Remedy: DEALERS WILL INSTALL SPRING CATCHER BRACKETS. OWNER NOTIFICATION BEGAN OCTOBER 23, 2001. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE …

AIR BAGS:FRONTAL:SENSOR/CONTROL MODULE-INACTIVE

VEHICLE DESCRIPTION: PASSENGER VEHICLES. THE AIR BAG SENSOR WIRING PIGTAIL INSULATION CAN BECOME BRITTLE AND CRACK OVER TIME DUE TO ACCUMULATION OF WATER IN THE PIGTAIL PROTECTIVE CONVOLUTE IN COMBINATION WITH HIGH UNDERHOOD TEMPERATURES RELATED TO THE ROUTING OF THE WIRING PIGTAIL NEAR THE RADIAT…

Risk: IN SOME CASES, THE AIR BAG WARNING LIGHT CAN ILLUMINATE AND THE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM DISABLED.

Remedy: DEALERS WILL INSTALL AIR BAG SENSORS WITH REVISED WIRING INSULATION. IN ADDITION, VEHICLES WHICH HAVE THE AIR BAG WARNING LIGHT ILLUMINATED WILL HAVE A NEW AIR BAG DIAGNOSTIC MONITOR INSTALLED.

EXTERIOR LIGHTING:HEADLIGHTS:SWITCH

VEHICLE DESCRIPTION: PASSENGER VEHICLES. THE TERMINALS AT THE HEADLIGHT SWITCH AND WIRING HARNESS CONNECTOR CAN EXPERIENCE HEAT DAMAGE AS A RESULT OF OVERHEATING.

Risk: THE DAMAGE COULD RESULT IN DISTORTION OF THE TERMINAL CAUSING AN OPEN CIRCUIT IN THE INSTRUMENT PANEL ILLUMINATION, PARKING LAMP, AND TAIL LAMP CIRCUITS.

Remedy: DEALERS WILL INSTALL A HEADLAMP SWITCH WIRING CONNECTOR CONTAINING BRONZE TERMINALS AND AN INSPECTION, AND REPLACEMENT IF NECESSARY, OF THE HEADLAMP SWITCH.

EXTERIOR LIGHTING:HEADLIGHTS

VEHICLE DESCRIPTION: PASSENGER VEHICLES. THE TEXT AND/OR GRAPHICS FOR THE VEHICLE HEADLAMP AIMING INSTRUCTIONS PROVIDED IN THE OWNER GUIDES ARE NOT SUFFICIENTLY CLEAR. THIS DOES NOT MEET THE REQUIREMENTS OF FMVSS NO. 108, "LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT."

Risk: IF THE HEADLAMP ASSEMBLIES ARE REPLACED, CUSTOMERS MAY BE CONFUSED BY THE AIMING INSTRUCTIONS PROVIDED IN THE OWNER GUIDES CAUSING THE HEADLAMPS TO BE IMPROPERLY AIMED.

Remedy: OWNER GUIDES CONTAINING REVISED AIMING INSTRUCTIONS WILL BE MAILED TO OWNERS OF THESE VEHICLES.

VEHICLE SPEED CONTROL:CABLES

VEHICLE DESCRIPTION: PASSENGER VEHICLES EQUIPPED WITH THE TRACTION CONTROL OPTION. THE THROTTLE CABLES WERE DAMAGED DURING VEHICLE ASSEMBLY LEADING TO FRAYING OR SEPARATION OF THE THROTTLE CABLE.

Risk: THIS CONDITION COULD PREVENT THE ENGINE FROM RETURNING TO IDLE.

Remedy: DEALERS WILL REPLACE THE THROTTLE CABLE WITH A REVISED DESIGN THAT IS LESS SUSCEPTIBLE TO BENDING OR KINKING DURING INSTALLATION.

FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY:FILLER PIPE AND CAP

THE FUEL TANK FILLER PIPE OPENING REINFORCEMENT, CONSTRUCTED FROM TWO SEPARATELY MOLDED PIECES, CAN LEAK AT THE WELD.

Risk: FUEL LEAKAGE CAN RESULT IN A FIRE.

Remedy: DEALERS WILL REPLACE THE FUEL TANK ASSEMBLIES WITH UNITS CONTAINING ONE-PIECE MOLDED REINFORCEMENTS.

POWER TRAIN:AUTOMATIC TRANSMISSION:LEVER AND LINKAGE:FLOOR SHIFT

VEHICLE DESCRIPTION: PASSENGER VEHICLES. THE FLOOR SHIFT AUTOMATIC TRANSMISSION CONTROL CAN BE DAMAGED IF SUBJECTED TO CERTAIN INTERIOR CLEANING PRODUCTS. THE GEAR POSITION INDICATOR CAN DETERIORATE AND NOT CORRECTLY INDICATE THE ACTUAL GEAR POSITION.

Risk: THIS CONDITION CAN RESULT IN INCORRECT GEAR SELECTION.

Remedy: DEALERS WILL REPLACE THE AUTOMATIC TRANSMISSION FLOOR SHIFT CONTROL.

SEAT BELTS:FRONT:ANCHORAGE

CRACKS HAVE BEEN FOUND IN THE FRONT SAFETY BELT OUTBOARD ANCHOR TABS DUE TO A COMBINATION OF HYDROGEN EMBRITTLEMENT OF THE TAB AND STRESS INTRODUCED DURING ATTACHMENT OF THE ANCHOR TAB TO THE SEAT FRAME. THIS DOES NOT CONFORM WITH THE REQUIREMENTS OF FMVSS NO. 210, "SEAT BELT ASSEMBLY ANCHORAGES."

Risk: CONSEQUENCE OF NON-COMPLIANCE: A FRACTURE OR SEPARATION IN THIS AREA WOULD REDUCE THE LOAD THAT THE ANCHOR AND THE FRONT SAFETY BELT ANCHORAGES COULD SUSTAIN, INCREASING THE RISK OF INJURY IN A VEHIC…

Remedy: DEALERS WILL INSPECT AND INSTALL AN ANCHOR TAB REINFORCEMENT OR REPLACEMENT OF THE COMPLETE FRONT SEAT BELT ASSEMBLY IF AN ANCHOR TAB IS FOUND TO HAVE FRACTURED.

FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY:FILLER PIPE AND CAP

A METAL SHIELD ON THE OUTSIDE OF THE PLASTIC FUEL FILLER PIPE CAN DEVELOP A STATIC ELECTRICAL CHARGE DURING REFUELING OF THE VEHICLE.

Risk: A STATIC CHARGE CAN DISCHARGE AND SERVE AS AN IGNITION SOURCE FOR FUEL VAPORS IN THE AREA OF THE FILLER PIPE, RESULTING IN A FLASH VAPOR IGNITION AND A VEHICLE FIRE.

Remedy: DEALERS WILL INSPECT AND, IF NECESSARY, MODIFY THE VEHICLES BY ADDING A GROUND STRAP BETWEEN THE FILLER PIPE SHIELD AND THE BODY.

FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY:FILLER PIPE AND CAP

THE FUEL TANK FILLER PIPE OPENING REINFORCEMENT CAN LEAK AT THE WELD.

Risk: FUEL LEAKAGE CAN RESULT IN A FIRE.

Remedy: DEALERS WILL INSPECT AND, AS APPROPRIATE, REPLACE THE FUEL TANKS.

VISIBILITY:WINDSHIELD

THE GLASS TEMPERING PROCESS ON THE RIGHT HAND REAR DOOR WINDOWS WAS NOT CORRECTLY PERFORMED. THIS DOES NOT MEET THE REQUIREMENTS OF FMVSS NO. 205, "GLAZING MATERIALS."

Risk: CONSEQUENCE OF NON-COMPLIANCE: IF THE WINDOW BREAKS, THE GLASS FRAGMENTS OF THE REAR WINDOWS EXCEED THE SIZE SPECIFICATIONS OF FMVSS NO. 205.

Remedy: DEALERS WILL REPLACE THE RIGHT REAR DOOR GLASS.

FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY:FILLER PIPE AND CAP

VEHICLE DESCRIPTION: PASSENGER VEHICLES. THE FUEL FILLER PIPE VENT HOSE MAY HAVE LESS THAN THE INTENDED LEVEL OF OZONE RESISTANCE, WHICH COULD RESULT IN THE HOSE BECOMING BRITTLE AND CRACKING.

Risk: A CRACKED HOSE COULD RESULT IN FUEL LEAKAGE WHEN THE VEHICLE IS BEING FUELED.

Remedy: DEALERS WILL INSTALL A FUEL FILLER VENT HOSE CONTACTING THE APPROPRIATE BLEND OF PVC AND NITRILE RUBBER.

FUEL SYSTEM, OTHER:STORAGE

VEHICLE DESCRIPTION: BI-FUEL VEHICLES MODIFIED TO RUN ON EITHER GASOLINE OR COMPRESSED NATURAL GAS (CNG). THE NATURAL GAS FUEL TANKS HAVE A SOLENOID SHUT-OFF VALVE THAT STOPS FUEL FLOW FROM THE FUEL TANK IN THE EVENT OF CERTAIN MODERATE TO SEVERE COLLISIONS. IF THE VEHICLE IS IN A COLLISION AND T…

Risk: FUEL LEAKAGE IN THE PRESENCE OF AN IGNITION SOURCE COULD RESULT IN A FIRE.

Remedy: FORD HAS REQUESTED OWNERS OF THESE VEHICLES TO HAVE THE CNG FUEL SYSTEM DISABLED UNDER A PREVIOUS RECALL CAMPAIGN AND TO ONLY USE GASOLINE FUEL UNTIL A PERMANENT CORRECTIVE ACTION IS DEVELOPED. OWNER…

FUEL SYSTEM, OTHER:STORAGE:TANK ASSEMBLY

VEHICLE DESCRIPTION: BI-FUEL VEHICLES. THESE VEHICLES MAY HAVE A FUEL TANK FILLER PIPE GROMMET THAT COULD HAVE BEEN DAMAGED DURING THE INSTALLATION OF THE BI-FUEL SYSTEM. IF THE GROMMET IS DAMAGED, FUEL COULD LEAK. FUEL LEAKAGE IN THE PRESENCE OF AN IGNITION SOURCE COULD RESULT IN A FIRE. DEAL…

Risk: IF THE GROMMET IS DAMAGED, FUEL COULD LEAK. FUEL LEAKAGE IN THE PRESENCE OF AN IGNITION SOURCE COULD RESULT IN A FIRE.

Remedy: DEALERS WILL REPLACE THE FUEL TANK FILLER PIPE GROMMET.

VEHICLE SPEED CONTROL

VEHICLE DESCRIPTION: PASSENGER VEHICLES. THE ACCELERATOR CABLE MAY HAVE BEEN MANUFACTURED WITH A BURR ON OR NEAR THE END OF THE CABLE SLEEVE INTERIOR. THIS BURR COULD FRAY THE CORE WIRE RESULTING IN THE ACCELERATOR NOT RETURNING TO IDLE WHEN THE ACCELERATOR IS RELEASED.

Risk: THIS CONDITION CAN RESULT IN THE THROTTLE STICKING, BINDING, OR CAUSING HIGH ENGINE RPM.

Remedy: DEALERS WILL INSTALL A REVISED ACCELERATOR CABLE THAT HAS A FLARED CONDUIT SLEEVE END AND MOLDED ON END FITTING.

ELECTRICAL SYSTEM:IGNITION:SWITCH

VEHICLE DESCRIPTION: PASSENGER VEHICLES BUILT WITH AUTOMATIC TRANSMISSIONS WHICH UTILIZE A PARK/LOCK SOLENOID. IT IS POSSIBLE TO ROTATE THE IGNITION KEY TO THE LOCK POSITION AND REMOVE THE KEY WITHOUT THE SHIFT LEVER AND TRANSMISSION BEING IN PARK. THESE VEHICLES DO NOT COMPLY WITH THE REQUIREM…

Risk: THIS COULD RESULT IN A CRASH AND POSSIBLE PERSONAL INJURY.

Remedy: DEALERS WILL INSPECT THESE VEHICLES. VEHICLES THAT HAVE UNITS WITH IGNITION KEYS REMOVABLE IN GEAR POSITIONS OTHER THAN PARK, WILL HAVE THE STEERING COLUMN REPLACED.

EQUIPMENT:OTHER:LABELS

VEHICLE DESCRIPTION: PASSENGER VEHICLES. AN INCORRECT LABEL WAS INSTALLED ON THE DRIVER SIDE REAR DOOR. THIS LABEL CONTAINS INSTRUCTIONS FOR THE ACTIVATION OF THE CHILDPROOF SAFETY LOCKS.

Risk: THE OPERATOR OF THE VEHICLE MAY BELIEVE THE CHILDPROOF SAFETY LOCK WAS ACTIVATED WHEN IT WAS NOT, POTENTIALLY ALLOWING THE DOOR TO BE OPENED FROM THE INSIDE.

Remedy: OWNERS WILL BE PROVIDED WITH A REPLACEMENT LABEL AND INSTALLATION INSTRUCTIONS.

SEAT BELTS

VEHICLE DESCRIPTION: PASSENGER VEHICLES, LIGHT DUTY TRUCKS, SPORT UTILITY VEHICLES, AND MINI VANS EQUIPPED WITH TRW SEAT BELT BUCKLE ASSEMBLIES. THE BUCKLE BASE OF THESE SEAT BELT ASSEMBLIES WERE NOT PROPERLY HEAT TREATED AND THEREFORE DO NOT PASS THE LOAD BEARING REQUIREMENT OF FEDERAL MOTOR VEHI…

Risk: IN THE EVENT OF A VEHICLE CRASH, THE OCCUPANT MAY NOT BE PROPERLY RESTRAINED.

Remedy: DEALERS WILL INSPECT THE DATE CODE ON CERTAIN SEAT BELT BUCKLES OF YOUR VEHICLE AND REPLACE ALL SEAT BELT BUCKLES THAT FALL WITHIN THE SUSPECT DATE CODE RANGE. OWNER NOTIFICATION BEGAN OCTOBER 26, 20…

SERVICE BRAKES, HYDRAULIC:POWER ASSIST:VACUUM

VEHICLE DESCRIPTION: PASSENGER VEHICLES BUILT WITH AN INCORRECT POWER BRAKE BOOSTER AND MASTER CYLINDER ASSEMBLY.

Risk: IF EITHER THE MASTER CYLINDER OR POWER BRAKE BOOSTER IS SUBSEQUENTLY SERVICED WITH ONLY ONE OF THE CORRECT BRAKE BOOSTER OR MASTER CYLINDER PARTS, BRAKE PERFORMANCE WOULD BE REDUCED.

Remedy: DEALERS WILL INSTALL THE CORRECT CONTOUR BRAKE BOOSTER AND MASTER CYLINDER IN EACH OF THESE VEHICLES. OWNER NOTIFICATION BEGAN JANUARY 28, 2002. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEAL…