1999 Mercury Cougar electrical system problems

Defect

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 THE WIRING HARNESS CONNECTOR. THE DAMAGE COULD, OVER TIME, CAUSE INCREASED RESISTANCE IN THE CONNECTOR AND, DUE TO SUBSEQUENT TERMINAL RELAXATION, RESULT IN AN OPEN CIRCUIT CONDITION.

Consequence

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 SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT FORD AT 1-800-392-3673.

Defect

VEHICLE DESCRIPTION: PASSENGER VEHICLES EQUIPPED WITH 2.5L V6 ENGINES. THE BATTERY CABLE WAS MISROUTED AND ITS ATTACHMENT TO THE ALTERNATOR CABLE WAS UNDER-TORQUED. IF MISROUTED, THE CABLE COULD CONTACT THE POWER STEERING LINE AND THE INSULATION COULD WEAR, RESULTING IN AN ELECTRICAL SHORT.

Consequence

THE SHORT COULD POTENTIALLY RESULT IN A FIRE, STALLING, OR A NO-START CONDITION.

Remedy

DEALERS WILL INSPECT THE BATTERY CABLE TO THE ALTERNATOR FOR DAMAGE AND, IF IT IS DAMAGED, WILL REPLACE THE CABLE. ADDITIONALLY, THE ROUTING OF THE CABLE WILL BE CORRECTED, AS NECESSARY, AND A ROUTING CLIP WILL BE ADDED. ALSO THE TORQUE ON THE ALTERNATOR ATTACHMENT OF THE CABLE WILL BE CHECKED AND, AS REQUIRED, WILL BE TIGHTENED TO SPECIFICATION. OWNER NOTIFICATION BEGAN MARCH 22, 2001. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT FORD AT 1-800-392-3673.