1978 Mercury Zephyr problems

Defect

CERTAIN FEDERAL-MOGUL AFTERMARKET FUEL PUMPS SOLD UNDER THE BRAND NAMES OF CARTER, ACCUFLOW, NAPA, TRUFLOW, PARTS DEPO, AND PARTS MASTER, SHIPPED BETWEEN AUGUST 2006 AND JULY 2007 FOR USE ON THE VEHICLES LISTED ABOVE. THE FUEL PUMP DIAPHRAGM IN CERTAIN PRODUCTION RUNS MAY HAVE BEEN IMPROPERLY INSTALLED OR INADEQUATELY TESTED WHICH MAY CAUSE THE FUEL PUMP TO LEAK.

Consequence

A LEAKING FUEL PUMP COULD CREATE A VEHICLE FIRE HAZARD.

Remedy

FEDERAL-MOGUL WILL NOTIFY OWNERS AND REPLACE THE DEFECTIVE FUEL PUMPS FREE OF CHARGE. THE RECALL BEGAN ON OCTOBER 15, 2007. OWNERS CAN CONTACT FEDERAL-MOGUL AT 248-354-7700.

Defect

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.

Defect

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.

Defect

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.

Defect

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.

Defect

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.

Defect

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.

Defect

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.

Defect

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.

Defect

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.

Defect

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.