Mercury Villager Recalls — All NHTSA Recall Campaigns

FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY

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 SHO…

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

Remedy: DEALERS WILL REPLACE THE VENT HOSE.

VISIBILITY:DEFROSTER/DEFOGGER/HVAC SYSTEM

LEAVES AND OTHER FOREIGN MATERIAL CAN ENTER THROUGH THE COWL PANEL AIR INTAKE DURING OPERATION OF THE FRONT HEATER AND/OR AIR CONDITIONING SYSTEM RESULTING IN A BUILD-UP OF MATERIAL IN THE PLENUM. THIS CAN LEAD TO NOISE, ODORS, OR IN SOME CASES, IGNITION OF THESE MATERIALS.

Risk: A VEHICLE FIRE COULD OCCUR.

Remedy: DEALERS WILL INSTALL AN ADDITIONAL HEATER/AIR CONDITIONING SYSTEM INTAKE SCREEN.

SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:MASTER CYLINDER

THE SERVICE BRAKE MASTER CYLINDER WAS NOT PROPERLY ASSEMBLED OR COULD HAVE BEEN DAMAGED BY THE EVACUATION AND FILLING OF THE BRAKE SYSTEM AT THE ASSEMBLY PLANT.

Risk: THIS CAN RESULT IN A PARTIAL BRAKE SYSTEM FAILURE DUE TOINTERNAL MASTER CYLINDER LEAKAGE WHICH CAN CAUSE LOSS OF BRAKING ON TWO OF THEFOUR WHEELS. IF THIS OCCURS, THERE WOULD BE INCREASED BRAKE PEDAL …

Remedy: A NEW BRAKE MASTER CYLINDER WILL BE INSTALLED.

SEAT BELTS

ONE OR BOTH OF THE BOLTS SECURING THE AUTOMATIC SEAT BELT RESTRAINT SYSTEM TRACKS TO THE B-PILLARS WERE NOT ADEQUATELY TIGHTENED.

Risk: THIS CONDITION CAN RESULT IN THE AUTOMATIC SEAT BELTSYSTEM TRACK JOINTS HAVING LESS THAN DESIGN STRENGTH, AND INCREASE THE RISK OFINJURY TO THE SEAT OCCUPANT IN THE EVENT OF A COLLISION OR SUDDEN STOP…

Remedy: DEALERS WILL TIGHTEN THE PASSIVE RESTRAINT SYSTEM TRACK MOUNTING BOLTS.

FUEL SYSTEM, GASOLINE:DELIVERY:HOSES, LINES/PIPING, AND FITTINGS

FUEL FILLER HOSES MAY HAVE BEEN CUT PRIOR TO INSTALLATION BY A UTILITY KNIFE USED TO OPEN THE SHIPPING BOX.

Risk: FUEL LEAKAGE CAN RESULT IF THE CUT EXTENDED THROUGH THETHICKNESS OF THE HOSE WALL. LEAKING FUEL CAN RESULT IN A FIRE IF EXPOSEDTO A SOURCE OF IGNITION.

Remedy: REPLACE THE FUEL FILLER HOSE.

EXTERIOR LIGHTING:TAIL LIGHTS

THE REAR LAMP SOCKET MAY NOT ILLUMINATE BECAUSE THE METAL CAN IN THE LAMP SOCKET MOVES OR SEPARATES FROM THE PLASTIC SOCKET HOUSING.

Risk: 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 S…

Remedy: DEALERS WILL INSTALL A REVISED REAR LAMP SOCKET AND WIRING ASSEMBLIES.

STEERING:RACK AND PINION

VEHICLE DESCRIPTION: MINI VANS. ONE OR MORE OF THE FIVE BOLTS THAT MOUNT THE RACK AND PINION STEERING GEAR TO THE VEHICLE MAY HAVE BEEN INCORRECTLY TIGHTENED.

Risk: THERE COULD BE A LOOSENESS IN THE STEERING, WHICH MAY BE ACCOMPANIED BY NOISE OR VIBRATION.

Remedy: DEALERS WILL INSPECT THE VEHICLES AND, IF THE BOLTS ARE MISSING, WILL REPLACE THE STEERING GEAR MOUNTING BOLTS. ALL BOLTS WILL BE TIGHTENED TO THE SPECIFIED TORQUE. OWNER NOTIFICATION BEGAN NOVEMBER…

FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY:MOUNTING

VEHICLE DESCRIPTION: MINI VANS. THE FUEL TANK RETENTION STRAP (TWO STRAPS PER VEHICLE) CAN BREAK AT THE SPOT WELDS CAUSING AN UNDERBODY RATTLE.

Risk: THERE IS ALSO A POTENTIAL FOR FUEL TANK SEPARATION OR FUEL LEAK, INCREASING THE RISK OF A FIRE.

Remedy: DEALERS WILL REPLACE THE FUEL TANK RETENTION STRAPS.

SEATS

AN OUT-OF-SPECIFICATION CONDITION IN THE SEAT CABLE ROLLER PULLEY ASSEMBLY CAN ALLOW THE CABLE THAT CONNECTS THE SEAT ADJUST LEVER TO THE LATCH TO BE PINCHED IN THE ROLLER ASSEMBLY.

Risk: CONSEQUENCE OF NON-COMPLIANCE: THIS CONDITION CAN PREVENT THE LATCH ON THE LEFT SIDE FROM FULLY ENGAGING THE SEAT RAIL. THIS DOES NOT COMPLY WITH THE REQUIREMENT OF FMVSS NO. 207, "SEATING SYSTEMS."

Remedy: DEALERS WILL REPLACE A COMPONENT IN THE THIRD ROW SLIDING BENCH SEAT LATCH ASSEMBLY.

VISIBILITY:WINDSHIELD

THE WINDSHIELDS WERE MARKED WITH A "PROTOTYPE" DESIGNATION AND NOT MARKED AS REQUIRED BY FMVSS NO. 205, "GLAZING MATERIALS."

Risk: 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.

VISIBILITY:POWER WINDOW DEVICES AND CONTROLS

VEHICLE DESCRIPTION: MINI VANS. THESE VEHICLES WERE PRODUCED WITH POWER WINDOWS THAT CAN BE CLOSED AFTER THE IGNITION KEY IS TURNED TO THE "OFF" POSITION AND THE RIGHT FRONT (PASSENGER) DOOR IS OPENED. THIS DOES NOT MEET THE REQUIREMENTS OF FMVSS 118, "POWER-OPERATED WINDOW SYSTEMS."

Risk: THERE IS THE POTENTIAL FOR UNSUPERVISED CHILDREN TO OPERATE THE POWER WINDOWS, INCREASING THE RISK OF PERSONAL INJURY TO THE CHILD.

Remedy: OWNERS WILL BE PROVIDED WITH A LABEL REMINDING OWNERS NOT TO LEAVE CHILDREN UNATTENDED BECAUSE THE POWER WINDOWS CAN OPERATE FOR 15 MINUTES AFTER THE VEHICLE IGNITION HAS BEEN TURNED OFF UNLESS THE DR…

ELECTRICAL SYSTEM:12V/24V/48V BATTERY

VEHICLE DESCRIPTION: PASSENGER MINI VANS EQUIPPED WITH AUTOMOTIVE BATTERIES SUPPLIED BY GNB TECHNOLOGIES. THESE BATTERIES HAVE A DEFECTIVE NEGATIVE POST THAT CAN CAUSE ACID LEAKAGE AND RELATED CORROSION DAMAGE.

Risk: THIS CONDITION CAN CAUSE A CATASTROPHIC FAILURE OF THE BATTERY WHICH COULD LEAD TO AN ENGINE FIRE OR BATTERY EXPLOSION.

Remedy: DEALERS WILL REPLACE THESE BATTERIES. UNTIL A NEW BATTERY IS OBTAINED, OWNERS SHOULD NOT ATTEMPT TO "JUMP START" THESE BATTERIES.

FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY:MOUNTING

THE FOUR RUBBER FUEL LINE CONNECTOR HOSES THAT ARE SUPPLIED TO FORD WITH THE FUEL TANK ASSEMBLY WERE IMPROPERLY MANUFACTURED. THESE HOSES CAN DEVELOP CRACKS OR SPLITS RESULTING IN FUEL LEAKAGE.

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

Remedy: DEALERS WILL INSPECT THE FUEL TANK ASSEMBLY FOR THE SUSPECT DATE CODES AND REPLACE THE FOUR RUBBER FUEL CONNECTOR HOSES IF NECESSARY.

EXTERIOR LIGHTING:TAIL LIGHTS

VEHICLE DESCRIPTION: MINIVANS. THE TAIL LIGHT SOCKET MAY HAVE BEEN IMPROPERLY MOLDED, RESULTING IN THE LOCKING TAB HAVING INSUFFICIENT FORCE TO RETAIN THE BULB.

Risk: IF THE BULB FALLS OUT OF THE SOCKET, THE BRAKE OR TAIL LAMP FUNCTION CANNOT OCCUR.

Remedy: DEALERS WILL REPLACE THE TAIL LAMP SOCKETS.

SEATS

VEHICLE DESCRIPTION: MINI VANS. THE AFFECTED VEHICLES MAY HAVE A SECOND ROW RIGHT HAND SIDE CAPTAIN CHAIR THAT HAS INADEQUATE LUBRICATION OF THE EASY ENTRY AND EXIT LATCH SYSTEM. IN SOME CASES, THE ACTUATOR SPRING IN THE LATCH COULD DEFORM AFTER REPEATED USE, CAUSING THE LATCH TO REMAIN IN THE UN…

Risk: AN UNLATCHED SEAT TRACK COULD RESULT IN AN INCREASED RISK OF INJURY IN THE EVENT OF A VEHICLE CRASH.

Remedy: DEALERS WILL REPLACE THE SEAT TRACK FOR THE SECOND ROW RIGHT HAND SIDE CAPTAIN'S CHAIR, WHICH INCLUDES THE EASY ENTRY AND EXIT LATCH MECHANISM.

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…

SEAT BELTS:FRONT:BUCKLE ASSEMBLY

VEHICLE DESCRIPTION: MINI VANS. THESE VEHICLES MAY HAVE THE PLASTIC TRIM COVER AROUND THE BASE OF THE FRONT SEAT SAFETY BELT BUCKLE TRAPPED BETWEEN THE SHOULDER OF THE RESTRAINT ANCHORAGE BOLT AND THE SEAT PEDESTAL. THIS COULD EVENTUALLY ALLOW THE SEAT BELT BUCKLE BOLT TO LOOSEN.

Risk: IN THE EVENT OF A CRASH, THE OCCUPANT SEATED IN THAT LOCATION MAY NOT BE ADEQUATELY RESTRAINED, INCREASING THE RISK OF PERSONAL INJURY.

Remedy: DEALERS WILL INSPECT THE SEAT BELT BUCKLE ASSEMBLY ATTACHMENT. SOME BELT BUCKLE ASSEMBLIES MAY REQUIRE REPLACEMENT.