Mercury ZEPHYR recalls by model year

Reported: 1977-09-22 (September 22, 1977) · Model years: 1978

THE FRONT DISC BRAKE ROTORS INSTALLED ON THE INVOLVED VEHICLES MAY HAVE BEEN IMPROPERLY MANUFACTURED SO THAT THEY CONTAIN CRACKS. THESE CRACKED ROTORS COULD FRACTURE DURING VEHICLE BRAKING AND CAUSE BRAKE PULL AND AFFECT VEHICLE DIRECTIONAL CONTROL.

Remedy: DEALER WILL REPLACE BOTH FRONT DISC BRAKE ROTORS ON INVOLVED VEHICLES, WITHOUT CHARGE TO OWNERS.

Reported: 1977-09-22 (September 22, 1977) · Model years: 1978

THE INVOLVED VEHICLES MAY BE IN NON-COMPLIANCE TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 105, "HYDRAULIC BRAKE SYSTEMS", DUE TO INSTALLATION OF INCORRECT REAR AXLE ASSEMBLIES. CONSEQUENTLY, EARLY REAR WHEEL LOCK-UP UNDER LIGHT LOADING CONDITIONS COULD RESULT CAUSING VEHICLE DIRECTIONAL INSTABILITY. REAR BRAKING EFFECTIVENESS WOULD ALSO BE REDUCED.

Remedy: DEALER WILL INSPECT AND, IF NECESSARY, INSTALL THE CORRECT REAR AXLE ASSEMBLY WITHOUT CHARGE TO OWNER.

Reported: 1977-09-22 (September 22, 1977) · Model years: 1978

THE INVOLVED VEHICLES MAY HAVE BEEN INCORRECTLY EQUIPPED WITH MANUAL BRAKES INSTEAD OF POWER BRAKES. CONSEQUENTLY, A NON-COMPLIANCE TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 105, "HYDRAULIC BRAKE SYSTEMS", MAY EXIST.

Remedy: DEALER WILL REMOVE THE MANUAL BRAKE COMPONENTS AND INSTALL POWER BRAKE COMPONENTS ON ALL INVOLVED VEHICLES, WITHOUT CHARGE.

Reported: 1977-10-12 (October 12, 1977) · Model years: 1978

ON SOME OF THE INVOLVED VEHICLES, THE TRANSMISSION PARKING PAWL MAY NOT ENGAGE THE PARKING GEAR WHEN THE TRANSMISSION SELECTOR LEVER IS PLACED IN THE "PARK" POSITION. THIS CONDITION IS ATTRIBUTABLE TO EXCESSIVE FREE PLAY IN THE TRANSMISSION SHIFT LINKAGE ADJUSTMENT.

Remedy: DEALER WILL INSPECT AND PROPERLY ADJUST THE SHIFT LINKAGE, AT NO CHARGE.

Reported: 1977-12-15 (December 15, 1977) · Model years: 1978

THE INVOLVED VEHICLES ARE EQUIPPED WITH AIR CONDITIONING UNITS WHICH CONTAIN BLOWER MOTOR RESISTOR WIRES WHICH ARE IMPROPERLY POSITIONED. AS A RESULT, UNDER CERTAIN CONDITIONS THE POLYPROPYLENE CASE MATERIAL COULD BECOME OVERHEATED AND EVENTUALLY IGNITE, ESPECIALLY IF THE BLOWER MOTOR SWITCH IS IN THE LOW OR MEDIUM POSITION.

Remedy: DEALER WILL MODIFY THE INVOLVED UNITS AS FOUND NECESSARY.

Reported: 1978-01-10 (January 10, 1978) · Model years: 1978

BECAUSE OF ITS POSITION, THE WIRING ASSEMBLY MAY CHAFE AGAINST THE COWL-TO-BRAKE PEDAL SUPPORT BRACE WHICH IS LOCATED UNDER THE INSTRUMENT PANEL.

Remedy: THE DEALER WILL INSTALL PROTECTIVE SHIELDS ON THE BRAKE PEDAL SUPPORT BRACE AND PERFORM REPAIRS, IF NECESSARY.

Reported: 1978-06-19 (June 19, 1978) · Model years: 1978

TRANSMISSION SHIFT CONTROL RODS WERE INSTALLED THAT WERE INTENDED FOR USE WITH THE STEERING COLUMNS OF A PRIOR DESIGN LEVEL. ATTACHMENT OF THE SHIFT CONTROL ROD WITH THE STEERING COLUMN SHIFT LEVER GROMMET WILL ALLOW RELATIVE MOVEMENT BETWEEN THESE PARTS. CONTINUED USAGE COULD RESULT IN GROMMET WEAR AND DETERIORATION OF THE SHIFT CONTROL FUNCTION, WITH THE POTENTIAL FOR STARTING IN GEAR OR AN INABILITY TO ENGAGE THE PARKING GEAR.

Remedy: DRIVER WILL INSPECT AND, IF NECESSARY, INSTALL NEW TRANSMISSION SHIFT LINKAGE PARTS, WITHOUT CHARGE TO OWNER.

Reported: 1978-06-27 (June 27, 1978) · Model years: 1978

AN IMPROPER TRANSMISSION SHIFT BRACKET WAS INSTALLED WHICH, BECAUSE OF ITS DESIGN, COULD CONTACT AND ABRADE THE FUEL HOSE. FUEL LEAKAGE AND POSSIBLE ACCUMULATION OF FUEL ON A SURFACE BENEATH A PARKED VEHICLE COULD RESULT.

Remedy: THE DEALER WILL REPLACE THE TRANSMISSION SHIFT BRACKET AND ITS RELATED PARTS, INCLUDING THE FUEL HOSE IF FOUND NECESSARY, FREE OF CHARGE.

Reported: 1978-08-07 (August 7, 1978) · Model years: 1978

THE WINDSHIELD WIPER DRIVE LINKAGE ON THE AFFECTED VEHICLES MAY FRACTURE DUE TO METAL FATIGUE AS A RESULT OF REPEATED FLEXING OF THE DRIVE ARM ACROSS A STRESS SENSITIVE AREA. THIS CONDITION WILL RENDER THE WINDSHIELD WIPER SYSTEM INOPERATIVE.

Remedy: THE DEALER WILL INSTALL AN IMPROVED WINDSHIELD WIPER LINKAGE WITHOUT COST TO OWNER.

Reported: 1978-09-21 (September 21, 1978) · Model years: 1978

THE INVOLVED VEHICLES CONTAIN EMISSION CONTROL SYSTEMS THAT UTILIZE A PULSE AIR REED VALVE TO PERMIT AIR FLOW FROM THE AIR CLEANER TO THE EXHAUST MANIFOLD ON NEGATIVE PRESSURE PULSATIONS. THESE REED VALVES MAY FAIL UNDER COLD WEATHER CONDITIONS, CAUSING A BACKFLOW OF EXHAUST GAS INTO THE AIR CLEANER AND FUEL INDUCTION SYSTEM ON POSITIVE EXHAUST PULSES. THIS CAUSES AN OVERLY RICH AIR/FUEL MIXTURE, REDUCED FUEL ECONOMY AND REDUCED ENGINE PERFORMANCE. CONTINUED VEHICLE OPERATION MAY RESULT IN ENGINE STALLING OR OVERHEATING OF THE EXHAUST SYSTEM.

Remedy: THE DEALER WILL REPLACE THE PULSE AIR SYSTEM REED VALVE AND SILENCER WITHOUT CHARGE.

Reported: 1979-01-26 (January 26, 1979) · Model years: 1979

THE INVOLVED VEHICLES WERE BUILT WITH SAFETY COMPLIANCE CERTIFICATION LABELS THAT CONTAINED INCORRECT GVWR AND GAWR WEIGHT INFORMATION. THE GVWR"S COULD BE OVERSTATED BY UP TO 197 LBS., DUE TO AN ERROR IN THE REPORTING OF INCREMENTAL OPTION WEIGHTS USED TO DERIVE THE GVWR"S AND GAWR"S.

Remedy: THE OWNER HAS THE OPTION OF AFFIXING THE SUPPLIED LABELS HIMSELF OR BRINGING THE VEHICLE IN TO THE DEALER TO HAVE THEM AFFIXED.

Reported: 1979-05-15 (May 15, 1979) · Model years: 1979

THE INVOLVED VEHICLES WERE PRODUCED WITH BRAKE PUSH-ROD TO BRAKE PEDAL RETAINING PINS WHICH WERE NOT HEAT-TREATED AS SPECIFIED. THIS COULD ALLOW THE BRAKE PEDAL TO BECOME DISENGAGED FROM THE PUSH-ROD.

Remedy: DEALER WILL REPLACE THE SUSPECT BRAKE RETAINING PIN.

Reported: 1979-12-27 (December 27, 1979) · Model years: 1979

WINDSHIELDS MAY HAVE BEEN INSTALLED ON THESE VEHICLES WITHOUT THE APPLICATION OF A BUTYL PRIMER ON THE MOUNTING SURFACE OF THE GLAZING. THE PRIMER IS REQUIRED TO ENSURE ADEQUATE RETENTION OF THE WINDSHIELD TO ITS OPENING FLANGE. THIS CONSTITUTES A NON-COMPLIANCE WITH FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 212, "WINDSHIELD MOUNTING".

Remedy: DEALER WILL REINSTALL THE WINDSHIELD CORRECTLY WITHOUT CHARGE TO OWNER.

Reported: 1979-12-18 (December 18, 1979) · Model years: 1980

THE INVOLVED VEHICLES DO NOT CONFORM TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 105, "HYDRAULIC BRAKE SYSTEMS". REAR AXLE ASSEMBLIES INTENDED FOR OTHER VEHICLES MAY HAVE BEEN INSTALLED IN THE INVOLVED VEHICLES. THE WHEEL CYLINDERS MAY NOT BE THE CORRECT SIZE. THIS COULD AFFECT BRAKING PERFORMANCE.

Remedy: DEALER WILL REPLACE ANY INCORRECT WHEEL CYLINDERS WITHOUT CHARGE TO OWNER.

Reported: 1980-11-19 (November 19, 1980) · Model years: 1981

ON SOME OF THE INVOLVED VEHICLES, THE BRAKE PUSHROD TO BRAKE PEDAL RETAINING PINS MAY BE MISSING OR LOOSE. INSECURELY INSTALLED OR MISSING RETAINERS COULD RESULT IN DISENGAGEMENT OF THE BRAKE PUSHROD AND TOTAL LOSS OF SERVICE BRAKING.

Remedy: DEALER WILL INSPECT AND, IF NECESSARY, INSTALL A BRAKE PEDAL RETAINING PIN.

Reported: 1982-10-13 (October 13, 1982) · Model years: 1982, 1983

THE PARK LEVER ON THE INVOLVED VEHICLES CONTAINS A DEFECTIVE SPRING WHICH COULD PREVENT AUTOMATIC ENGAGEMENT OF THE PARKING GEAR.

Remedy: THE PARK ACTUATING LEVER ROD SPRING WILL BE REPLACED WITH AN UPGRADED SPRING WITHOUT CHARGE TO OWNER.

Reported: 1983-02-24 (February 24, 1983) · Model years: 1983

THE SHIFT INDICATOR MAY NOT ACCURATELY REFLECT THE SHIFT SELECTOR POSITION. SOME VEHICLES WERE PRODUCED WITH TRANSMISSION CONTROL SELECTOR TUBE RETAINING CLIPS THAT MAY NOT BE HARD ENOUGH. THE CLIP MAY LOOSEN OR FALL OFF, AND THE SELECTOR TUBE MAY BECOME DISPLACED.

Remedy: THE DEALER WILL REPLACE THE TRANSMISSION CONTROL SELECTOR TUBE RETAINING CLIP AT NO CHARGE TO OWNER.