1989 Mercury Sable problems

ALLEGED DEFECTIVE TIE RODS

ALLEGED DEFECTIVE TIE RODS

BROKEN TIE RODS

POLYCAST ROAD WHEEL CRACKS

UNDERBODY FUEL LINE FAILS

BROKEN TIE RODS

SUB-FRM/UNIBODY ABSOR.FAIL

SUB-FRM/UNIBODY ABSOR.FAIL

POWER STEERING LEAKS/FIRES

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.

SEAT BELTS:FRONT:BUCKLE ASSEMBLY

THIS IS NOT A SAFETY RECALL IN ACCORDANCE WITH FEDERAL REGULATION 573. HOWEVER, IT IS DEEMED A SAFETY IMPROVEMENT CAMPAIGN BY THE AGENCY. FORD IS INITIATING AN OWNER NOTIFICATION PROGRAM THAT WILL PROVIDE AN EXTENDED WARRANTY, 12 YEARS AND UNLIMITED MILEAGE, FOR ALL SEAT BELT BUCKLES WITH FUNCTIONAL CONCERNS.

Risk: IN THE EVENT OF A COLLISION, THE OCCUPANT OF THE SEAT MAY NOT BE PROPERLY RESTRAINED AND PERSONAL INJURY COULD OCCUR.

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.

SEAT BELTS:FRONT:BUCKLE ASSEMBLY

THE RIGID MOUNTED SAFETY BELT BUCKLES ARE DEFECTIVE IN THREE WAYS. FIRST, A FASTENED SAFETY BELT BUCKLE WILL NOT UNLATCH WHEN THE RELEASE BUTTON IS DEPRESSED. THIS RESULTS FROM INTERFERENCE BETWEEN THE BUCKLE EJECTOR FINGER AND THE BUCKLE TONGUE WINDOW. THE SECOND DEFECT IS THE SAFETY BELT BUCKLE MAY NOT LATCH. THE THIRD POSSIBLE DEFECT IS THAT THE TONGUE MAY BE RETAINED BY THE BUCKLE, BUT IT MAY NOT BE LATCHED SUFFICIENTLY TO PROVIDE OCCUPANT PROTECTION.

Risk: AN INSUFFICIENTLY LATCHED OR UNLATCHED SAFETY BELTINCREASES THE RISK OF INJURY TO SEAT OCCUPANTS IN THE EVENT OF A SUDDEN STOP ORACCIDENT. IF THE SAFETY BELT BUCKLE WILL NOT UNLATCH, IT WILL NOT ALLOW THEOCCUPANT TO GET OUT OF THE VEHICLE IN AN EMERGENCY SITUATION.

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.

SEATS

THE POWER SEAT SWITCH WIRING IS ROUTED OVER RATHER THAN UNDER THE FRONT SEAT SUPPORT BRACE, ALLOWING DAMAGE BY SEAT CUSHION SPRING ENDS WHEN SEAT IS OCCUPIED.

Risk: POWER SEAT SWITCH WIRING INSULATION MAY BECOME ABRADED,OR PUNCTURED, AND AN ELECTRICAL SHORT COULD OCCUR THAT COULD RESULT IN A FIREIN THE SEAT CUSHION MATERIAL.

EXTERIOR LIGHTING

FRONT SIDE MARKER LAMPS WERE UNINTENTIONALLY EQUIPPED WITH CLEAR BULBS, INSTEAD OF AMBER COLORED BULBS AS SPECIFIED IN FMVSS 108.

Risk: VEHICLES WOULD NOT COMPLY WITH STANDARD.

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.

Seats And Restraints

SEAT BELT BUCKLES ON THESE VEHICLES MAY EXPERIENCE CONDITIONS WHEREBY THE BUCKLE MAY NOT UNLATCH WHEN THE RELEASE BUTTON IS DEPRESSED OR MAY NOT LATCH, OR IN SOME CASES, MAY LATCH PARTIALLY BUT NOT SUFFICIENTLY TO PROVIDE OCCUPANT RESTRAINT IN THE EVENT OF A COLLISION. NOTE: ONLY END-RELEASE BUCKLES ON "RIGID" MOUNTINGS ARE SUSCEPTIBLE TO THIS MALFUNCTION. CORRECTION: FACTORY INSTALLED END-RELEASE SEAT BELT BUCKLES WILL BE REPLACED WITH REDESIGNED BUCKLES.

Emissions

NOTE: VEHICLES EQUIPPED WITH 3.8 LITRE ENGINES. THESE VEHICLES MAY NOT COMPLY WITH C.M.V.S.S 1105 - EVAPORATIVE EMISSIONS. CORRECTION: PURGE VALVE AND HOSE ASSEMBLY WILL BE REPLACED 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.

Electrical

IMPROPER ROUTING OF THE POWER SEAT SWITCH WIRING WILL ALLOW THE WIRING TO BE CONTACTED AND POTENTIALLY DAMAGED BY THE SEAT CUSHION SPRING ENDS WHEN THE SEAT IS OCCUPIED. THIS COULD ABRADE OR PUNCTURE THE WIRING AND CAUSE AN ELECTRICAL SHORT WHICH COULD IN TURN RESULT IN A FIRE. CORRECTION: POWER SEAT SWITCH WIRING WILL BE REROUTED AND DAMAGED WIRING WILL BE REPLACED.

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.