1986 Mercury Sable problems

REAR LOWER SUBFRAME ASSEMBLY

TO DETERMINE WHETHER THE CARS THAT WERE NOT INCLUDED IN THE SAFETY RECALL 93V-106 SHOULD BE RECALLED DUE TO THE SAME FAILURE PHENOMENON, AND TO DETERMINE IF THERE IS REMEDY FAILURE ISSUE

POLYCAST ROAD WHEEL CRACKS

SUB-FRM/UNIBODY ABSOR.FAIL

SUB-FRM/UNIBODY ABSOR.FAIL

STORAGE COMPAR SUFFOCATION

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FIRES IN IGNITION SWITCH

STORAGE COMPAR SUFFOCATION

DOOR HANDLES BREAKAGE

STRUCTURE:FRAME AND MEMBERS

VEHICLE DESCRIPTION: PASSENGER VEHICLES ORIGINALLY SOLD OR CURRENTLY REGISTERED IN CONNECTICUT, DELAWARE, DISTRICT OF COLUMBIA, ILLINOIS, INDIANA, IOWA, KANSAS, KENTUCKY, MAINE, MARYLAND, MASSACHUSETTS, MICHIGAN, MINNESOTA, MISSOURI, NEBRASKA, NEW HAMPSHIRE, NEW JERSEY, NEW YORK, OHIO, PENNSYLVANIA, RHODE ISLAND, VERMONT, VIRGINIA, WEST VIRGNIA, AND WISCONSIN. THE REAR LOWER SUBFRAME MOUNT PLATE NUT CAN EXPERIENCE STRESS CORROSION CRACKING IF SUBJECTED TO LONG TERM EXPOSURE TO ROAD SALTS. THIS CAN RESULT IN FRACTURE AND LOSS OF THE STRUCTURAL INTEGRITY OF THE SUBFRAME MOUNT ATTACHMENT. DETACHMENT OF THE BODY MOUNTS AT THE REAR CORNERS OF THE SUBFRAME, WHICH SUPPORTS THE ENGINE AND TRANSMISSION, ALLOWS THE REAR CORNERS OF THE SUBFRAME TO DROP.

Risk: IF BOTH REAR CORNERS DROP, STEERING WOULD BECOME SUDDENLY VERY DIFFICULT, AFFECTING VEHICLE CONTROL AND INCREASING THE RISK OF A CRASH.

SUSPENSION:FRONT:SHOCK ABSORBER

THE ARC WELDS ON THE SWAY BAR BRACKET, WHERE IT ATTACHES TO THE STRUT RESERVE TUBE, DID NOT FUSE PROPERLY.

Risk: OVER TIME, A PORTION OF THE BRACKET CAN TEAR AWAY FROM THE STRUT, FALLING INTO AND PUNCTURING THE TIRE OR CAUSING DAMAGE TO THE WHEEL, WHICH COULD RESULT IN AN ACCIDENT.

STRUCTURE:FRAME AND MEMBERS

VEHICLE DESCRIPTION: TAURUS AND SABLES BUILT FROM 10-14-85 THROUGH 8-19-88, AND LINCOLN CONTINENTALS BUILT FROM 11-4-87 THROUGH 9-30-88 (EXCEPT 1989 - 1991 2.5L TAURUS AND 1989 - 1992 SHO). THE AFFECTED CARS WERE ORIGINALLY SOLD OR CURRENTLY REGISTERED IN THE FOLLOWING STATES: CONNECTICUT, ILLINOIS, INDIANA, MAINE, MASSACHUSETTS, MICHIGAN, NEW HAMPSHIRE, NEW JERSEY, NEW YORK, OHIO, PENNSYLVANIA, RHODE ISLAND, VERMONT, AND WISCONSIN. THE BODY MOUNTS AT THE REAR CORNERS OF THE SUBFRAME, WHICH SUPPORTS THE ENGINE AND TRANSMISSION, MAY BECOME DETACHED DUE TO CORROSION OF THE SUBFRAME MOUNT RETAINING PLATE. THIS WOULD ALLOW THE REAR CORNERS OF THE SUBFRAME TO DROP.

Risk: IF ONE OF THE REAR CORNERS DROPS, ONLY MINOR INDICATIONS OF A MALFUNCTION SUCH AS A CLUNKING NOISE OR SLIGHT CHANGE IN STEERING WHEEL ALIGNMENT ARE NOTICEABLE. HOWEVER, IF BOTH REAR CORNERS OF THE SUBFRAME DROP, STEERING BECOMES VERY DIFFICULT, WHICH COULD ADVERSELY AFFECT VEHICLE CONTROL AND POSSIBLY RESULT IN AN ACCIDENT.

WHEELS

CHILDREN CAN ACCIDENTALLY LOCK THEMSELVES IN THE FOOTWELL AREA OF THE REAR-FACING THIRD SEAT, OR IN THE STORAGE COMPARTMENT IN STATION WAGONS NOT EQUIPPED WITH AN OPTIONAL THIRD SEAT. ONCE THE COMPARTMENT IS CLOSED IT CANNOT BE OPENED FROM THE INSIDE.

Risk: THERE IS A DANGER OF AIR DEPRIVATION, HYPERTHERMIA,AND/OR PANIC RESPONSE TO A CHILD WHO HAS LOCKED HIMSELF OR HERSELF INTO THECOMPARTMENT, WITH THE POSSIBILITY OF ASPHYXIATION.

SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:DISC:ROTOR

FRONT DISC BRAKE ROTORS OF THE SUBJECT VEHICLES MAY EXPERIENCE SEVERE CORROSION IF OPERATED IN AREAS WHERE CALCIUM CHLORIDE AND SODIUM CHLORIDE ARE USED EXTENSIVELY.

Risk: SEVERELY CORRODED ROTORS MAY FRACTURE OR SEPARATE NEARTHE INNER EDGES OF THE BRAKE DISCS RESULTING IN REDUCED BRAKING EFFECTIVENESS,HIGHER THAN NORMAL PEDAL EFFORTS, LOUD GRINDING NOISES, AND MODERATE PULLS WHENTHE BRAKES ARE APPLIED. REDUCED BRAKING EFFECTIVENESS MAY INCREASE MINIMUMSTOPPING DISTANCES, POSSIBLY RESULTING IN AN ACCIDENT.

FUEL SYSTEM, GASOLINE:DELIVERY:HOSES, LINES/PIPING, AND FITTINGS

SPRING LOCK FUEL LINE COUPLING MAY NOT BE PROPERLY ENGAGED.

Risk: COUPLING COULD DISENGAGE DUE TO FUEL PRESSURE,VIBRATION, AND ENGINE MOVEMENTS; THIS WOULD CAUSE LOSS OF FUEL WHICH, INPRESENCE OF AN IGNITION SOURCE, CREATES A FIRE RISK.

VISIBILITY:WINDSHIELD WIPER/WASHER:MOTOR

ROAD SALT INDUCED EROSION OF THE WIPER MOTOR CONDUCTOR STRIPS COULD CAUSE LOCALIZED THERMAL STRESS WITHIN THE GLASS.

Risk: GLASS COULD FRACTURE WHILE STATION WAGON IS BEING DRIVENOR PARKED, CREATING A RISK OF INJURY TO OCCUPANTS OR SUDDEN DISTRACTION TO THEDRIVER.

VISIBILITY

THE RIGHT QUARTER WINDOWS MAY CONTAIN GLASS WHICH WAS IMPROPERLY TEMPERED. THIS GLASS MAY YIELD PIECES LARGER THAN THE MAXIMUM ALLOWED BY FMVSS 205, GLAZING MATERIAL. CONSEQUENCE OF DEFECT: IN CASE OF AN ACCIDENT THESE LARGE PIECES OF GLASS MAY SERIOUSLY INJURE THE OCCUPANTS OF THE CAR.

Steering

On certain vehicles located in Manitoba, Ontario, Quebec, New Brunswick, Nova Scotia, Prince Edward Island, and Newfoundland & Labrador, the lower sub frame mount plate nut may corrode and fail due to exposure to road salt. This could result in loss of structural integrity of the subframe mount attachment. Detachment of the body mounts at the rear corners of the sub frame which supports the engine and transmission, allows the rear corners of the sub frame to drop. Should both rear corners drop, steering control would be adversely affected. Correction: Dealers will install subframe rear mount bolts, reinforcement plate and plate nuts.

Structure

On certain vehicles with 3.0 Litre and 3.8 Litre engines, the body mounts on the rear corners of the subframe which supports the engine and transmission may become detached due to corrosion of the rear lower mount retaining plates, allowing the rear corners of the subframe to drop. Should this occur, steering could become very difficult, thereby adversely affecting vehicle control. Correction: modified lower body mounts and attaching bolts will be installed on affected vehicles.

Structure

Note: Station wagon vehicles only. Young children left unattended in the vehicle could lock themselves in the footwell area of the rear-facing third seat (or the underfloor storage compartment in station wagons not equipped with the optional third seat). Once the compartment is closed, it cannot be opened from the inside, and there is the danger of air deprivation, excessive body heat and panic response to a child who may have closed himself or herself in the compartment. Correction: A modified latch will be installed which does not have a self-latching feature and allows the compartment cover to be pushed open from the inside.

Engine

THIS RECALL SUPERSEDES RECALL 90-27 FOR VEHICLES IN THE MARITIMES. THE THROTTLE MAY STICK IN AN OPEN POSITION DUE TO LINKAGE BINDING CAUSED BY CORROSION. THIS WOULD CAUSE THE ENGINE TO RUN AT HIGHER THAN IDLE SPEED WHEN THE THROTTLE IS RELEASED AND COULD ADVERSELY AFFECT DRIVER CONTROL RESULTING IN A POSSIBLE CRASH. CORRECTION: A STAINLESS STEEL SLEEVE, WHICH WILL BE PLACED OVER THE HUB ON THE THROTTLE BODY ASSEMBLY, AND A SECONDARY THROTTLE LEVER TO FIT THE SLEEVE, ALONG WITH OTHER MOUNTING PARTS, WILL BE INSTALLED ON AFFECTED VEHICLES.

Brakes

THE COMPOSITE CONSTRUCTION FRONT BRAKE ROTORS ON THESE VEHICLES MAY CORRODE, WEAKEN AND FRACTURE, RESULTING IN A REDUCTION OF BRAKING PERFORMANCE. SUCH A FRACTURE WOULD RESULT IN LOSS OF BRAKING AT THE CORRESPONDING FRONT WHEEL WHICH COULD IN TURN RESULT IN INCREASED STOPPING DISTANCE AND A POSSIBLE CRASH. CORRECTION: FRONT BRAKE ROTORS WILL BE REPLACED.

Engine

RANGER/BRONCO II - 2.9 LITRE ENGINES TAURUS/SABLE - 3.0 LITRE ENGINES NOTE: VEHICLES LOCATED IN NEWFOUNDLAND, NOVA SCOTIA, NEW BRUNSWICK AND PRINCE EDWARD ISLAND. THE THROTTLE MAY STICK IN AN OPEN POSITION DUE TO LINKAGE BINDING CAUSED BY CORROSION. THIS WOULD CAUSE THE ENGINE TO RUN AT HIGHER THAN IDLE SPEED WHEN THE THROTTLE IS RELEASED AND COULD ADVERSELY AFFECT DRIVER CONTROL RESULTING IN A POSSIBLE CRASH. CORRECTION: ON VEHICLES WITH 2.9 LITRE ENGINES, DEALERS WILL CLEAN, MODIFY AND LUBRICATE THE HUB PIN AND LEVER BUSHINGS WITH A MARINE-TYPE ANTI-SEIZE GREASE. ADDITIONALLY, ON VEHICLES WITH 3.0 LITRE ENGINES, THE HUB PIN LEVER ASSEMBLY WILL BE REPLACED. NOTE: THIS RECALL HAS BEEN SUPERSEDED BY RECALL NO. 91021.

Emissions

THESE VEHICLES MAY NOT COMPLY WITH C.M.V.S.S. 1103 - EXHAUST EMISSIONS. THE CENTRAL FUEL INJECTOR (CFI) MAY OPERATE RICH DURING CERTAIN OPERATING CONDITIONS. CORRECTION: IMPROVED CFI FUEL INJECTORS WILL BE INSTALLED AND IDLE SPEED WILL BE ADJUSTED.

Fuel System

ON VEHICLES WITH EFI OR CFI, THE SPRING-LOCK FUEL LINE COUPLING USED TO CONNECT THE FUEL SUPPLY AND RETURN LINES TO THE EFI FUEL RAILS OR TO THE CFI THROTTLE BODIES AS WELL AS OTHER FUEL LINE CONNECTIONS NEAR THE DASH PANELS ON SOME VEHICLES, COULD DISENGAGE DURING VEHICLE USE. SHOULD THIS OCCUR, LOSS OF FUEL WILL RESULT, PROVIDING THE POTENTIAL FOR A VEHICLE FIRE. CORRECTION: COUPLING RETAINER CLIPS WILL BE INSTALLED ON AFFECTED VEHICLES. NOTE: ESCORT VEHICLES ARE EQUIPPED WITH EFI AND CFI. LYNX VEHICLES ARE EQUIPPED WITH CFI ONLY. EFI - ELECTRONIC FUEL INJECTION CFI - CENTRAL FUEL INJECTION