1996 MERCURY VILLAGER Engine And Engine Cooling Problems

WHILE DRIVING ANY SPEED CONSUMER HEARD A TICKING NOISE COMING FROM THE ENGINE. DEALERSHIP DID NOT RESOLVE THE PROBLEM. *AK

Mileage: 82,177

I NOTICED THERE WAS AN EXHAUST SMELL SEEPING INTO THE VAN, I DID SOME RESEARCH ON THE INTERNET AND FOUND THAT IT WAS A COMMON PROBLEM WITH QUEST'S AND VILLAGER'S SNAPPED EXHAUST MANIFOLD STUDS. I CHECKED UNDER THE HOOD AND SURE ENOUGH THERE WERE 2 STUDS BROKEN AND MISSING. I CALLED SEVERAL DEALERS AND GOT QUOTES AND FOUND A NISSAN DEALER TO DO IT FOR $800 THEY SEEM TO HAVE MORE EXPERINCE DOING IT SINCE IT ALSO IS A PROBLEM WITH PATHFINDERS AND MAXIMAS. I CALLED FORD AND THEY FLAT OUT REFUSED TO HELP OUT AT ALL!

Mileage: 81,600

THE STUD BOLTS ARE (IS) BROKEN ON EXHAUST MANIFOLD. EXHAUST FUMES ARE LEAKING AND COLD AIR MAY ENTER HEAD. REPAIR IS EXTREMELY HIGH BECAUSE OF POSITION OF BOLTS. WE ARE AFRAID TO DRIVE IT BUT CANNOT STOP USING IT. ALSO WE CANNOT AFFORD TO FIX IT. *NLM

Mileage: 90,000

EXHAUST GASES ESCAPING INTO THE PASSENGER COMPARTMENT BECAUSE OF AN EXHAUST MANIFOLD BOLT FAILURE. *JB

Mileage: 115,000

WHILE DRIVING AT ANY SPEED VEHICLE COMPLETELY SHUT OFF. *AK

EXHAUST FUMES ENTERED THE PASSENGER CABIN. THE PROBLEM WAS WITH THE FRONT AND REAR EXHAUST MANIFOLD. *PH *SCC *NLM

Mileage: 71,000

MY 1996 MERCURY VILLAGER HAS BEEN DIAGOSED AS HAVING BROKEN EXHAUST MANIFOLD BOLTS. AFTER SEARCHING THE WEB, IT'S BECOME APPARENT THAT THIS IS AN EXTREMELY COMMON PROBLEM WITH CERTAIN MODEL YEARS OF THE MERCURY VILLAGER, INCLUDING MINE. THE DESIGN OF THIS PART OF THE CAR IS DEFINITELY FLAWED BECAUSE OF THE COMMONALITY OF THIS PROBLEM.

Mileage: 60,050

EXHAUST MANIFOLD BOLTS SHEARED OFF, ALLOWING EXHAUST FUMES TO SEEP INTO INTERIOR OF VAN. HAVE TO DRIVE WITH WINDOWS CRACKED OPEN TO AVOID GETTING SICK. AFTER INTERNET SEARCH FOUND THERE ARE THOUSANDS OF OTHERS WITH THIS SAME PROBLEM, BUT FORD REFUSES TO DO ANYTHING OR HELP OUT WITH THE COSTS WHICH WILL BE SEVERAL 1000 $$. *JB

Mileage: 81,000

INTAKE MANIFOLD BOLT SHEARED OFF WHILE TRAVELING ON HIGHWAY. EXHAUST FUMES WERE LEAKING FROM PIPE AREA. DEALERSHIP IS AWARE OF PROBLEM.*AK

VEHICLE HAS STALLED WITHOUT WARNING AT LEAST 12 TIMES OVER SEVERAL YEARS. THIS HAPPENS AT ANY SPEED AND HAS ALWAYS HAPPENED IN HOT WEATHER. THE LAST SEVERAL TIMES WERE ON A BUSY, CURVY HIGHWAY WITH NO ROOM TO PULL OFF ROAD AND ALMOST LED TO AN ACCIDENT. THE VILLAGER'S FUEL PUMP BECOMES VERY NOISY WHEN TRYING TO RESTART ENGINE. AFTER ABOUT 15 TO 20 MINUTES IT WILL RESTART. PLEASE INFORM ME OF WHAT THE PROBLEM COULD BE. IT HAS NEVER HAPPENED IN COLD WEATHER. I AM AFRAID AN ACCIDENT COULD HAPPEN. THERE IS NO WARNING AT ALL.*AK

VEHICLE HAS STALLED 7-8 TIMES AT ANY SPEED, DEALER CANNOT REMEDY THE PROBLEM.*AKWHILE STARTING THE VEHICLE, CONSUMER SMELLS GAS, THE FUEL PUMP FAILED, CONSUMER HAD IT REPLACED, AND IS SEEKING REIMBURSEMENT. *JG

WHILE DRIVING VEHICLE STARTED CHOKING AND THEN IT CUT OFF. CONTACTED DEALER, CANNOT FIND CAUSE. *AK

WHILE DRIVING OIL LIGHT CAME ON, AND THEN AL LOUD NOISE CAME FROM ENGINE, CAUSING ENGINE TO DRAG. CONSUMER HAD OIL CHANGE TWICE, AND FIXED PROBLEM TEMPORARILY. *AK

WHILE DRIVING ON HIGHWAY ENGINE STALLED WITHOUT PRIOR WARNING. VEHICLE HAD TO BE TOWED. THEN, AT DEALER MECHANIC SAID THAT PROBLEM WAS DUE TO AN ENGINE BLOWN THAT HAD CRACKED THE BLOCK. ENGINE NEEDED TO BE REPLACED. PLEASE PROVIDE MORE INFORMATION. *AK

A DAY AFTER TAKING VEHICLE FOR MANUFACTURER'S RECALL AWF40C-F 00 S 59 REPAIRS FILLER HOSE HAD TO BE CHANGED BECAUSE IT COULD CAUSE A FIRE. WHEN CONSUMER WAS DRIVING ABOUT 40 MPH ENGINE STARTED JUMPING. THEN, CAUGHT ON FIRE JUST LIKE IT SAID IN RECALL. *AK THE VEHICLE HAD EXHAUST LEAK AT THE MANIFOLD. THE CONSUMER SAYS HE DOES NOT KNOW THE CAUSE OF THE FIRE. *YH

CONSUMER EXPERIENCING MOTOR PROBLEMS. *JB

CHECK ENGINE LIGHT ILLUMINATED, DEALER STATED EGR VALVE WAS DIRTY AND NEEDED CLEANED, HOWEVER LIGHT ILLUMINATED AGAIN AND WITH AN UNUSUAL NOISE, CONSUMER LEARNED THAT ENGINE WAS TO BE REPLACED AND MONIES SHOULD NOT HAVE BEEN PAID FOR EGR VALVE CLEANING AND BELT TENSIONER REPLACEMENT, CONSUMER IS REQUESTING REIMBURSEMENT FOR THOSE REPAIRS, AFTER ENGINE REPAIR CONSUMER NOTICED OD OFF LIGHT FLASHING, CHECK ENGINE LIGHT ILLUMINATED, WHINING NOISE FROM ENGINE, AND POWER STEERING MADE NOISE AS STEERING WHEEL WAS TURNED, ALL OF THIS HAPPENED BEFORE CONSUMER PUT VEHICLE IN DRIVE AND FEELS THESE ADDITIONAL FAILURES ARE DUE TO THE INSTALLMENT OF THE NEW ENGINE. *SLC

ENGINE NOISE, KIND OF LOUD. ALSO, ENGINE LIGHT CAME ON. CONTACTED DEALER, AND THE DEALER SAID THEY SHOULD REPLACE TENSIONER.*AK AFTER THE DEFECTIVE TENSIONER WAS REPLACED, THE DEALER INDICATED THAT THE ENGINE NEEDED TO BE REPLACED AS WELL. HOWEVER CHECK THE ENGINE LIGHT CAME ON AND STAYED ON AFTER THE ENGINE WAS REPLACED. THE AIR BAG LIGHT WAS FLASHING CONTINUOUSLY. *YH

ENGINE NOISE, KIND OF LOUD. ALSO, ENGINE LIGHT CAME ON. CONTACTED DEALER, AND THE DEALER SAID THEY SHOULD REPLACE TENSIONER.*AK AFTER THE DEFECTIVE TENSIONER WAS REPLACED, THE DEALER INDICATED THAT THE ENGINE NEEDED TO BE REPLACED AS WELL. HOWEVER CHECK THE ENGINE LIGHT CAME ON AND STAYED ON AFTER THE ENGINE WAS REPLACED. THE AIR BAG LIGHT WAS FLASHING CONTINUOUSLY. *YH

ENGINE DIED $5000 REPAIR SECRET SERVICE WARRANTY TO REPLACE NOT HONORED BY DEALER. *AK

HEAD CONTROL MODULE WIRE HARNESS IN BACK OF THE DASH PANEL BURNED UP. WIRES WERE COMPLETELY MELTED. *AK SEVERAL ELECTRICAL RELATED PROBLEMS: BATTERY FAILURE, OPEN CIRCUIT IN MAIN ENGINE HARNESS TO EGR SOLENOID, OVERHEAD LIGHT FAILED, POWER DOOR LOCKS WERE OPERATING BY THEMSELVES, POWER LOCKS WOULD NOT LOCK WITH THE SWITCH, REAR WINDSHILED WIPER SWITCH FAILED AND REAR WIPERS WOULD NOT STOP EVEN AFTER FUSE WAS REMOVED, SLIDING DOOR WOULD NOT OPEN WITH REMOTE OR SWITCH. CHECK ENGINE LIGHT ILLUMINATED. POWER STEERING PUMP NOISY AND WAS REPLACED. AIR CONDITIONER MOTOR FAILED. WHEN LOCKING VEHICLE WITH KEY, HORN WOULD OPERATE, KEYLESS ENTRY HAD JUST BEEN INSTALLED. *SLC

RECALL 00V419002/ FUEL TANK VENT HOSE, RECEIVED LETTER ON 17 FEB 2001. AT THAT TIME CONSUMER WAS TOLD BY DEALER PARTS WERE NOT AVAILABLE YET. ON FEB 26 2001, CONSUMER STARTED VEHICLE, AND AFTER A FEW MINUTES THERE WAS SMOKE . THEN FIRE STARTED UNDER HOOD. DEALER DENIES THIS COULD HAVE BEEN CAUSED BY FUEL TANK VENT HOSE. *AK

EXHAUST MANIFOLD BOLTS SHEARING OFF, REQUIRING DRILLING OUT, REPLACEMENT. INTERNET SEARCH REVEALS THAT QUEST, PATHFINDER, AND VILLAGER ALL HAVE SIMILAR AFFLICTION. MANUFACTURER HAS AGREED TO PAY FOR 80% OF REPAIR COST TO FIX IT, EVEN THOUGH VEHICLE IS OUT OF WARRANTY. $1000.00 TO $3,000 TO FIX. EXHAUST FUMES ARE SEEPING INTO CAB, REQUIRING OPENING OF WINDOWS. BY OFFERING TO PAY ARE THEY NOT ADMITTING THERE IS A PROBLEM? RECALL ISSUE?*AK

ENGINE OIL LIGHT INTERMITTENTLY FLASHING WHEN ENGINE IS COLD (AFTER STARTING). OIL LIGHT GOES OFF AFTER ENGINE IS WARMED UP. INTERMITTENT EXCESSIVE "ENGINE NOISE" WHEN ENGINE IS COLD (AFTER STARTING). MERCURY DEALERSHIP INDICATES "SLUDGE" IN ENGINE, RECOMMENDS REPLACEMENT OF ENGINE. LAST OIL CHANGE AT 29000 MILES AND PREVIOUSLY AT 24600 MILES. DEALERSHIP IS INDICATING ENGINE DAMAGE IS DUE TO INADEQUATE MAINTENANCE (I.E. OIL CHANGE FREQUENCY). FORD ISSUED A LETTER JANUARY 1997 (RECALL 96M89) WHICH DESCRIBES "PISTON SLAP" NOISE PROBLEM AND OFFERED TO EXTEND ENGINE WARRANTY TO 7 YEARS OR 100,000 MILES. DEALERSHIP IS CONTENDING THAT THE ENGINE DAMAGE IS NOT DUE TO THIS RECALL BUT OWNER MAINTENANCE. I WOULD LIKE TO KNOW IF YOU CAN PROVIDE ADDITIONAL DETAIL ON THE 96M89 RECALL NOTICE AND WHETHER OR NOT THE ENGINE DEFECT COVERED BY THE RECALL COULD PRECIPITATE THE ENGINE DAMAGE I AM EXPERIENCING AT 40,700 MILES. WHILE I UNDERSTAND THIS ISSUE IS NOT SAFETY RELATED ANY ASSISTANCE YOU COULD PROVIDE WOULD BE APPRECIATED. *AK

ENGINE OIL LIGHT INTERMITTENTLY FLASHING WHEN ENGINE IS COLD (AFTER STARTING). OIL LIGHT GOES OFF AFTER ENGINE IS WARMED UP. INTERMITTENT EXCESSIVE "ENGINE NOISE" WHEN ENGINE IS COLD (AFTER STARTING). MERCURY DEALERSHIP INDICATES "SLUDGE" IN ENGINE, RECOMMENDS REPLACEMENT OF ENGINE. LAST OIL CHANGE AT 29000 MILES AND PREVIOUSLY AT 24600 MILES. DEALERSHIP IS INDICATING ENGINE DAMAGE IS DUE TO INADEQUATE MAINTENANCE (I.E. OIL CHANGE FREQUENCY). FORD ISSUED A LETTER JANUARY 1997 (RECALL 96M89) WHICH DESCRIBES "PISTON SLAP" NOISE PROBLEM AND OFFERED TO EXTEND ENGINE WARRANTY TO 7 YEARS OR 100,000 MILES. DEALERSHIP IS CONTENDING THAT THE ENGINE DAMAGE IS NOT DUE TO THIS RECALL BUT OWNER MAINTENANCE. I WOULD LIKE TO KNOW IF YOU CAN PROVIDE ADDITIONAL DETAIL ON THE 96M89 RECALL NOTICE AND WHETHER OR NOT THE ENGINE DEFECT COVERED BY THE RECALL COULD PRECIPITATE THE ENGINE DAMAGE I AM EXPERIENCING AT 40,700 MILES. WHILE I UNDERSTAND THIS ISSUE IS NOT SAFETY RELATED ANY ASSISTANCE YOU COULD PROVIDE WOULD BE APPRECIATED.

ENGINE OIL LIGHT INTERMITTENTLY FLASHING WHEN ENGINE IS COLD (AFTER STARTING). OIL LIGHT GOES OFF AFTER ENGINE IS WARMED UP. INTERMITTENT EXCESSIVE "ENGINE NOISE" WHEN ENGINE IS COLD (AFTER STARTING). MERCURY DEALERSHIP INDICATES "SLUDGE" IN ENGINE, RECOMMENDS REPLACEMENT OF ENGINE. LAST OIL CHANGE AT 29000 MILES AND PREVIOUSLY AT 24600 MILES. DEALERSHIP IS INDICATING ENGINE DAMAGE IS DUE TO INADEQUATE MAINTENANCE (I.E. OIL CHANGE FREQUENCY). FORD ISSUED A LETTER JANUARY 1997 (RECALL 96M89) WHICH DESCRIBES "PISTON SLAP" NOISE PROBLEM AND OFFERED TO EXTEND ENGINE WARRANTY TO 7 YEARS OR 100,000 MILES. DEALERSHIP IS CONTENDING THAT THE ENGINE DAMAGE IS NOT DUE TO THIS RECALL BUT OWNER MAINTENANCE. I WOULD LIKE TO KNOW IF YOU CAN PROVIDE ADDITIONAL DETAIL ON THE 96M89 RECALL NOTICE AND WHETHER OR NOT THE ENGINE DEFECT COVERED BY THE RECALL COULD PRECIPITATE THE ENGINE DAMAGE I AM EXPERIENCING AT 40,700 MILES. WHILE I UNDERSTAND THIS ISSUE IS NOT SAFETY RELATED ANY ASSISTANCE YOU COULD PROVIDE WOULD BE APPRECIATED. *AK

ENGINE OIL LIGHT INTERMITTENTLY FLASHING WHEN ENGINE IS COLD (AFTER STARTING). OIL LIGHT GOES OFF AFTER ENGINE IS WARMED UP. INTERMITTENT EXCESSIVE "ENGINE NOISE" WHEN ENGINE IS COLD (AFTER STARTING). MERCURY DEALERSHIP INDICATES "SLUDGE" IN ENGINE, RECOMMENDS REPLACEMENT OF ENGINE. LAST OIL CHANGE AT 29000 MILES AND PREVIOUSLY AT 24600 MILES. DEALERSHIP IS INDICATING ENGINE DAMAGE IS DUE TO INADEQUATE MAINTENANCE (I.E. OIL CHANGE FREQUENCY). FORD ISSUED A LETTER JANUARY 1997 (RECALL 96M89) WHICH DESCRIBES "PISTON SLAP" NOISE PROBLEM AND OFFERED TO EXTEND ENGINE WARRANTY TO 7 YEARS OR 100,000 MILES. DEALERSHIP IS CONTENDING THAT THE ENGINE DAMAGE IS NOT DUE TO THIS RECALL BUT OWNER MAINTENANCE. I WOULD LIKE TO KNOW IF YOU CAN PROVIDE ADDITIONAL DETAIL ON THE 96M89 RECALL NOTICE AND WHETHER OR NOT THE ENGINE DEFECT COVERED BY THE RECALL COULD PRECIPITATE THE ENGINE DAMAGE I AM EXPERIENCING AT 40,700 MILES. WHILE I UNDERSTAND THIS ISSUE IS NOT SAFETY RELATED ANY ASSISTANCE YOU COULD PROVIDE WOULD BE APPRECIATED.

NO SUMMARY LISTED FOR ABOVE VEHICLE. *AK

HEAD BOLT SNAPPED INSIDE THE ENGINE, CAUSING DAMAGES INSIDE THE TIMING BELT GEARS AND LOCKING UP ENGINE. DEALER NOTIFIED. *AK

WHEN BUYING VAN I NOTICED A LOUD CLACKING NOISE IN ENGINE ON COLD STARTS. I SAID I DIDN'T WANT CAR. THEY SAID IF THEY PUT A NEW ENGINE IN CAR (23,000MI)WOULD I BUY IT. I SAID YES. THEY PUT A REBUILT ENGINE IN VAN INSTEAD AND DIDN'T TELL ME. NOW HAS 31,0000 MILES ON IT AND IS CLACKING AGAIN PLUS SHAKES CAR VIOLENTLY FIRST 6 TO 8 SECONDS WHEN STARTING COLD. (INTERMITTENTLY) MECHANIC SAID IT HAS BAD PISTON PROBLEMS. FORD MOTOR CO. REFUSES TO CORRECT PROBLEM. SAYS IT'S OUT OF WARRENTY. WHY SHOULD I HAVE TO PAY TO REPLACE THE SECOND BAD ENGINE IN THAT CAR. THEY REPLACED A BAD ENGINE WITH A BAD ENGINE. I SUGGESTED TRADING CAR IN FOR ANOTHER ONE AND THEY RELUCTANTLY OFFERED ME $4,000 TO $5,000 MAX AS TRADE IN BECAUSE THE CAR HAD A BAD ENGINE. I WAS WILLING TO PURCHASE A NEW 1999 VILLAGER($22,000+). I'M BEING SCREWED BADLY BY A COMPANY THAT REFUSES TO ACKNOWLEDGE IT HAS AN ENGINE PROGRAM PROBLEM. HELP ME PLEASE. DAVE MC MANUS. *AK

WHEN BUYING VAN I NOTICED A LOUD CLACKING NOISE IN ENGINE ON COLD STARTS. I SAID I DIDN'T WANT CAR. THEY SAID IF THEY PUT A NEW ENGINE IN CAR (23,000MI)WOULD I BUY IT. I SAID YES. THEY PUT A REBUILT ENGINE IN VAN INSTEAD AND DIDN'T TELL ME. NOW HAS 31,0000 MILES ON IT AND IS CLACKING AGAIN PLUS SHAKES CAR VIOLENTLY FIRST 6 TO 8 SECONDS WHEN STARTING COLD. (INTERMITTENTLY) MECHANIC SAID IT HAS BAD PISTON PROBLEMS. FORD MOTOR CO. REFUSES TO CORRECT PROBLEM. SAYS IT'S OUT OF WARRENTY. WHY SHOULD I HAVE TO PAY TO REPLACE THE SECOND BAD ENGINE IN THAT CAR. THEY REPLACED A BAD ENGINE WITH A BAD ENGINE. I SUGGESTED TRADING CAR IN FOR ANOTHER ONE AND THEY RELUCTANTLY OFFERED ME $4,000 TO $5,000 MAX AS TRADE IN BECAUSE THE CAR HAD A BAD ENGINE. I WAS WILLING TO PURCHASE A NEW 1999 VILLAGER($22,000+). I'M BEING SCREWED BADLY BY A COMPANY THAT REFUSES TO ACKNOWLEDGE IT HAS AN ENGINE PROGRAM PROBLEM. HELP ME PLEASE. DAVE MC MANUS. *AK

WHILE TRAVELING 75MPH VEHICLE MADE GRAVE NOISES & THEN DIED OUT. MANEUVERED TO SIDE OF ROAD. COULD NOT CHECK ENGINE OIL DUE TO DIP STICK NOT REMOVABLE. TOWED TO MECHANIC & INFORMED CONSUMER THA T UNDER HOOD FROZE UP DUE TO LACK OF LUBRICATION.*AK

I WAS GETTING ON THE EXPRESSWAY OVER IN THE PASSING LANE THE VAN MADE A NOISE I TURN DOWN THE RADIO TO LISTEN I LOST PRESSURE THE VAN SHUT DOWN . I HAD OIL ,WATER I JUST DONT UNDER STAND WHAT HAPPEN I WAS TOLD THAT I NEED AN ENGINE NEVER HAD A WARNING SIGN AND I ALWAYS KEEP MY OIL CHANGE AND OTHER ITEM ACORRDING MANUFACUTURER. *AK

CRANKSHAFT BROKE WHILE DRIVING AT 60 MPH , CAUSING POWER LOSS. THIS CONDITION COULD HAVE CAUSED A COLLISION ON THE FREEWAY. VEHICLE INSPECTED BY INDEPENDENT REPAIR SHOP, AND INFORMED CONSUMERTHAT CRANKSHAFT HAS HAD CRACKS IN SHAFT BEFORE THE BREAKAGE. ASKING NHTSA TO LOOK INTO THIS MATTER AND PROVIDE ADDITIONAL INFORMATION. *AK

DRIVING DOWN THE ROAD AT APPROXIMATELY 15MPH ENGINE STALLS. ALSO WHEN OPENING PASSENGER'S SIDE DOOR SOMETHING TRIGGERS INSIDE THE LOCK MECHANISM, WHICH CAUSES THE DOOR TO AUTOMATICALLY LOCK. *AK

WHILE MAKING A TURN THROUGH AN INTERSECTION THE STEERING AND BRAKES FAILED, THE DRIVER COASTED TO THE SIDE OF THE ROAD AND TRIED TO TURN THE KEY, THE VEHICLE DID NOT START, THEN THE DRIVER TURN THE VEHICLE OFF AND RESTARTED THE VEHICLE AND IT STARTED.

WHILE DRIVING AT HIGHWAY SPEED AND FOR A LONG PERIOD OF TIME, THE VEHICLE STALLS UNEXPECTEDLY ALMOST RESULTING AN ACCIDENT. WON'T RESTART FOR ABOUT A HALF AN HOUR. BEEN TO DEALER NUMEROUS TIMES. DEALER CANNOT DETERMINE PROBLEM. CAUSE UNKNOWN. *AK *ML

THERE IS A VERY STRONG SMELL OF FUEL VAPORS THAT FILTER THROUGH HOME WHEN VAN IS PARKED IN THE GARAGE OVER A 3 HOUR PERIOD. THE DEALER IS AWARE OF THE PROBLEM. THE VAN IS BEING CHECKED BY THE DEALERSHIP. *AK

HEAT SHIELD AROUND EXHAUST SYSTEM LOOSE.

WHILE DRIVING 40-50MPH THE VEHICLES COMPONENTS LOCK UP AND THE ENGINE GOES. DEALER HAS NOT BEEN ABLE TO DUPLICATE THE PROBLEM. *AK CONSUMER STATED THIS HAS HAPPENED 3 TO 4T TIMES NEARLY CAUSING ACCIDENTS.*JB

VAN STALLED.