1978 Mercury Zephyr Recalls

1. Recall Description

   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.

   Possible Effects

   Action

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

   Notes

   VEHICLE DESCRIPTION: PASSENGER VEHICLES EQUIPPED WITH 200 CID ENGINES,AUTOMATIC TRANSMISSIONS AND THERMACTOR PULSE AIR SUPPLY SYSTEMS.SYSTEM: EXHAUST; EMISSIONS SYSTEM.CONSEQUENCES OF DEFECT: OVERHEATING OF THE EXHAUST SYSTEM MAY LEAD TO SCORCHEDREAR SEATS AND CARPETS AND ASSOCIATED FUMES. ENGINE STALLING WOULD POSE ASAFETY HAZARD IN TRAFFIC, WHICH COULD LEAD TO A VEHICLE ACCIDENT.

   Recall Manufacture Dates

   1977-08-01 - 1978-04-01

   Vehicles Affected

   218500

2. Recall Description

   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.

   Possible Effects

   Action

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

   Notes

   VEHICLE DESCRIPTION: PASSENGER VEHICLES EQUIPPED WITH 2.3 LITER ENGINES,AUTOMATIC TRANSMISSIONS AND STEERING COLUMN MOUNTED SHIFT CONTROLS.SYSTEM: FUEL; FUEL LINES, HOSES.CONSEQUENCES OF DEFECT: IF AN IGNITION SOURCE IS PRESENT WHEN FUEL LEAKAGEOCCURS, A FIRE COULD START AND RESULT IN PERSONAL INJURY AND PROPERTY DAMAGE.

   Recall Manufacture Dates

   1978-06-01 - 1978-06-01

   Vehicles Affected

   180

3. Recall Description

   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.

   Possible Effects

   Action

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

   Notes

   VEHICLE DESCRIPTION: PASSENGER VEHICLES.SYSTEM: VISUAL; WINDSHIELD.CONSEQUENCES OF DEFECT: AN INOPERATIVE WINDSHIELD WIPER SYSTEM WOULD ADVERSELYAFFECT DRIVER VISIBILITY IN POOR WEATHER CONDITIONS. THIS COULD CONTRIBUTE TO AVEHICLE ACCIDENT.

   Recall Manufacture Dates

   -

   Vehicles Affected

   400000

4. Recall Description

   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.

   Possible Effects

   Action

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

   Notes

   VEHICLE DESCRIPTION: PASSENGER VEHICLES EQUIPPED WITH AUTOMATIC TRANSMISSIONSAND STEERING COLUMN MOUNTED SHIFT CONTROLS.SYSTEM: TRANSMISSION; SHIFT LINKAGE.CONSEQUENCES OF DEFECT: IF THE VEHICLE IS PARKED WITHOUT ENGAGING THE PARKINGBRAKE, IT COULD ROLL FREE, CAUSING INJURY AND DAMAGE TO PERSONS AND PROPERTY INITS PATH.NOTE: SINCE THE VEHICLE MAY INADVERTENTLY BE STARTED IN GEAR, THE PARKING BRAKESHOULD BE FIRMLY APPLIED WHILE STARTING THE ENGINE, PRIOR TO CORRECTION OF THEPROBLEM.

   Recall Manufacture Dates

   1978-06-01 - 1978-06-01

   Vehicles Affected

   358

5. Recall Description

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

   Possible Effects

   Action

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

   Notes

   VEHICLE DESCRIPTION: PASSENGER VEHICLES.SYSTEM: ELECTRICAL; MAIN WIRING ASSEMBLY.CONSEQUENCES OF DEFECT: LOSS OF POWER TO AN ACCESSORY OR TOTAL LOSS OFELECTRICAL POWER TO THE VEHICLE COULD OCCUR WITHOUT WARNING. LOSS OF VEHICLEMOBILITY AND, POSSIBLY, AN ACCIDENT COULD RESULT.

   Recall Manufacture Dates

   1977-08-01 - 1977-12-01

   Vehicles Affected

   185000

6. Recall Description

   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.

   Possible Effects

   Action

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

   Notes

   VEHICLE DESCRIPTION: PASSENGER VEHICLES EQUIPPED WITH AUTOMATIC TRANSMISSIONSAND STEERING COLUMN-MOUNTED SHIFT CONTROLS.SYSTEM: POWER TRAIN; PARKING PAWL.CONSEQUENCES OF DEFECT: IF THE CONDITION WERE TO OCCUR ON A VEHICLE ON WHICHTHE DRIVER HAD NOT ENGAGED THE PARKING BRAKE, THE VEHICLE COULD ROLL FREE ANDCAUSE PROPERTY DAMAGE AND PERSONAL INJURY.

   Recall Manufacture Dates

   -

   Vehicles Affected

   41000

7. Recall Description

   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.

   Possible Effects

   Action

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

   Notes

   VEHICLE DESCRIPTION: PASSENGER VEHICLES.SYSTEM: SUSPENSION; REAR AXLE ASSEMBLIES.CONSEQUENCES OF DEFECT: VEHICLE DIRECTIONAL INSTABILITY AND DECREASE IN REARBRAKING ACTION MAY CAUSE LOSS OF VEHICLE CONTROL AND AN ACCIDENT.

   Recall Manufacture Dates

   -

   Vehicles Affected

   18

8. Recall Description

   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.

   Possible Effects

   Action

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

   Notes

   VEHICLE DESCRIPTION: PASSENGER VEHICLES WITH 302 CID ENGINES.SYSTEM: SERVICE BRAKES; BRAKE COMPONENTS.CONSEQUENCES OF DEFECT: DEPENDING ON THE OPTIONAL EQUIPMENT INCLUDED ON THESEVEHICLES, MANUAL BRAKES MAY NOT BE ADEQUATE TO ENSURE SAFE STOPPING IN CERTAINDRIVING SITUATIONS AND A VEHICLE ACCIDENT COULD RESULT.

   Recall Manufacture Dates

   -

   Vehicles Affected

   72

9. Recall Description

   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.

   Possible Effects

   Action

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

   Notes

   VEHICLE DESCRIPTION: PASSENGER VEHICLES.SYSTEM: SERVICE BRAKES; FRONT DISC BRAKE ROTORS.CONSEQUENCES OF DEFECT: LOSS OF VEHICLE CONTROL AND AN ACCIDENT MAY RESULT.

   Recall Manufacture Dates

   -

   Vehicles Affected

   44638

10. Recall Description

    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.

    Possible Effects

    Action

    DEALER WILL MODIFY THE INVOLVED UNITS AS FOUND NECESSARY.

    Notes

    VEHICLE DESCRIPTION: PASSENGER VEHICLES.SYSTEM: AIR CONDITIONING; BLOWER MOTOR.CONSEQUENCES OF DEFECT: IF AN ENGINE FIRE STARTS AND SPREADS TO THE PASSENGERCOMPARTMENT, PASSENGERS COULD RECEIVE SERIOUS INJURIES.NOTE: UNTIL THE VEHICLE IS SERVICED, THE BLOWER MOTOR SHOULD NOT BE SET IN THELOW OR MEDIUM POSITIONS.

    Recall Manufacture Dates

    -

    Vehicles Affected

    6

11. Recall Description

    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.

    Possible Effects

    A LEAKING FUEL PUMP COULD CREATE A VEHICLE FIRE HAZARD.

    Action

    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.

    Notes

    THIS RECALL ONLY PERTAINS TO AFTERMARKET CARTER, NAPA, ACCUFLOW, TRU FLOW, PARTS MASTER, AND PARTS DEPOT BRAND FUEL PUMPS AND HAS NO RELATION TO ANY ORIGINAL EQUIPMENT INSTALLED ON THE LISTED MOTOR VEHICLES.CUSTOMERS MAY CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION''S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY: 1-800-424-9153); OR GO TO HTTP://WWW.SAFERCAR.GOV.

    Recall Manufacture Dates

    -

    Vehicles Affected

    34000