1978 Mercury ZEPHYR: complaints, problems and recalls

WHEN THE BRAKES WERE APPLIED SUDDENLY, THE SEAT BELTS DID NOT LOCK AS DESIGNED.*JB

Owner-reported narrative. 150,000 miles reported. Look up ODI 10009966 at NHTSA ↗

WIRES IN STEERING COLUMN SHORTED OUT RESULTING IN FIRE.

Owner-reported narrative. Look up ODI 545121 at NHTSA ↗

Reported: 1977-09-22 (September 22, 1977)

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.

Reported: 1977-09-22 (September 22, 1977)

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.

Reported: 1977-09-22 (September 22, 1977)

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.

Reported: 1977-10-12 (October 12, 1977)

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.

Reported: 1977-12-15 (December 15, 1977)

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.

Reported: 1978-01-10 (January 10, 1978)

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.

Reported: 1978-06-19 (June 19, 1978)

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.

Reported: 1978-06-27 (June 27, 1978)

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.

Reported: 1978-08-07 (August 7, 1978)

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.

Reported: 1978-09-21 (September 21, 1978)

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.