2002 Mercury Mountaineer

This investigation is being closed based on several considerations.By the most inclusive counting of all alleged rollaway incidents (i.e., counting all alleged rollaway incidents and assuming a singular failure mechanism), the incident rate is low, however during EA09-013, ODI identified a number of different failure mechanisms in 180 incidents related to the alleged defect.The highest rate for any particular failure mechanism, the failure of the Automatic Transmission Parking System, was 4.4/100K.The next-highest failure rate was for the BSI System, at 3.4/100K.For all identified failure mechanisms there has been a drastically declining trend including very few incidents occurring in recent years.Accordingly, this investigation is closed.The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist.For additional information regarding this investigation, see the complete closing resume in the document file for EA09-013. The ODI reports cited above can be reviewed at www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following identification (ODI) numbers:10168454, 10279630, 10280078.

ON SEPTEMBER 6, 2005, ODI RECEIVED A PETITION REQUESTING THAT THE AGENCY INVESTIGATE ALLEGATIONS OF ENGINE SPARK PLUG EJECTION IN CERTAIN MODEL YEAR 1997 THROUGH 2004 FORD VEHICLES WITH TRITON V-8 AND V-10 ENGINES.ODI RECEIVED A TOTAL OF 474 NON-DUPLICATIVE COMPLAINTS ON THE SUBJECT VEHICLES WHERE THE COMPLAINANT, OR THE DEALER REPAIRING THE VEHICLE, REPORTED THAT A SPARK PLUG DETACHED FROM THE CYLINDER AND/OR EJECTED FROM THE ENGINE.AS OF DECEMBER 8, 2005, ODI IS NOT AWARE OF ANY ALLEGATIONS WHERE THE ALLEGED DEFECT RESULTED IN A LOSS OF VEHICLE CONTROL, A CRASH, AN INJURY, OR A FATALITY IN ANY OF THE 10,319,810 SUBJECT VEHICLES.IN ADDITION, ODI IS AWARE OF ONLY TWO INCIDENTS WHERE THE VEHICLE STALLED WITHOUT RESTART.INFORMATION CONTAINED IN THE ODI CONSUMER COMPLAINTS AND OBTAINED FROM 72 TELEPHONE INTERVIEWS WITH COMPLAINANTS SHOWED THE FOLLOWING:(1) 99% OF THE COMPLAINTS WERE ON MY 1997 TO 2002 SUBJECT VEHICLES.(2) MOST THE COMPLAINANTS REPORTED HEARING A LOUD POP WHILE DRIVING OR UPON STARTING UP THE VEHICLE FOLLOWED BY A LOUD, REPETITIVE CLICKING OR POPPING SOUND.(3) MANY OF THE COMPLAINANTS REPORTED THAT THE POPPING SOUND WAS ACCOMPANIED BY SOME LOSS OF VEHICLE POWER; HOWEVER, IN 99% OF THE INCIDENTS REPORTED, THE VEHICLE DID NOT STALL.IN THE VERY FEW INCIDENTS WHERE THE VEHICLE DID STALL, MOST VEHICLES COULD BE RESTARTED.(4) ONLY A SMALL PERCENTAGE OF THE COMPLAINANTS CITED THAT THEY SMELLED GAS OR A SLIGHT BURNING SMELL WHEN THE INCIDENT OCCURRED.(5) IN ALL BUT A VERY FEW INCIDENTS, VEHICLE DAMAGE WAS LIMITED TO THE ENGINE.IN ONE INCIDENT, THE COMPLAINT REPORTED THAT THE FUEL RAIL WAS DAMAGED AND REPLACED AFTER ONE OF THE SPARK PLUGS EJECTED FROM THE ENGINE; HOWEVER, THE COMPLAINANT REPORTED THAT THE DAMAGE DID NOT RESULT IN ANY TYPE OF FUEL LEAK OR FIRE.IN ANOTHER INCIDENT, THE ONLY INCIDENT WHERE A FIRE WAS ALLEGED, THE COMPLAINANT REPORTED THAT NO FLUID LEAK WAS OBSERVED, BUT THAT A FIRE RESULTED AFTER THE SPARK PLUG HAD EJECTED FROM THE ENGINE AND HE HAD RESTARTED THE VEHICLE AND DRIVEN TO ANOTHER LOCATION.NONE OF THE COMPLAINANTS REPORTED ANY DAMAGE TO THE VEHICLE HOOD.(6) ONLY TWO COMPLAINANTS REPORTED THAT THEY OBSERVED WHAT APPEARED TO BE SOME DROPS OF FUEL COMING FROM THE CYLINDER WHERE THE SPARK PLUG HAD FAILED OR ON THE SPARK PLUG ITSELF; HOWEVER, EACH OF THESE COMPLAINANTS REPORTED THAT THERE WAS NO SMOKE OR FLAMES AS A RESULT OF HIS INCIDENT.AS THE PETITIONER NOTED, AND ODI?S ANALYSIS SHOWED, IT IS POSSIBLE FOR A SPARK PLUG TO DETACH FROM THE ENGINE CYLINDER THREADS IN THE SUBJECT VEHICLES.HOWEVER, ODI?S ANALYSIS OF 474 COMPLAINTS DESCRIBING SUCH INCIDENTS FOUND ONLY A VERY FEW ALLEGED ANY SAFETY-RELATED CONSEQUENCES.NONE OF THESE SHOWED ANY EVIDENCE OF A SERIOUS SAFETY CONSEQUENCE.GIVEN THE LARGE POPULATION AND RELATIVELY LONG EXPOSURE TIME OF THE SUBJECT VEHICLES, THE COMPLAINT ANALYSIS INDICATES THAT THE RISK TO MOTOR VEHICLE SAFETY FROM THE ALLEGED DEFECT IS VERY LOW.IN VIEW OF THE FOREGOING, IT IS UNLIKELY THAT NHTSA WOULD ISSUE AN ORDER FOR THE NOTIFICATION AND REMEDY OF THE ALLEGED DEFECT AT THE CONCLUSION OF THE INVESTIGATION REQUESTED IN THE PETITION.THEREFORE, IN VIEW OF THE NEED TO ALLOCATE AND PRIORITIZE NHTSA?S LIMITED RESOURCES TO BEST ACCOMPLISH THE AGENCY?S SAFETY MISSION, THE PETITION IS DENIED.

ON JULY 7, 2005, THE OFFICE OF DEFECTS INVESTIGATION (ODI) OPENED A PRELIMINARY EVALUATION TO INVESTIGATE ALLEGED STUCK THROTTLE COMPLAINTS IN CERTAIN MODEL YEAR (MY) 2002 FORD EXPLORER AND MERCURY MOUNTAINEER VEHICLES EQUIPPED WITH THE STANDARD AVAILABLE 4.0L SOHC V6 ENGINE.AT THAT TIME, ODI WAS AWARE OF 15 COMPLAINTS THAT ALLEGED STUCK ENGINE THROTTLE CAUSING UNWANTED VEHICLE ACCELERATION AND 1 ALLEGED CRASH AS A RESULT.SIX COMPLAINANTS REPORTED THAT THROTTLE CONTROL CABLE REPLACEMENT REMEDIED THE ALLEGED STUCK THROTTLE CONDITION.ADDITIONALLY, ODI WAS AWARE OF A TECHNICAL SERVICE BULLETIN ISSUED BY THE MANUFACTURER THAT REFERRED TO AN ACCELERATOR CABLE DESIGN CHANGE.ODI SENT A LETTER TO THE MANUFACTURER ON JULY 18, 2005 REQUESTING CERTAIN INFORMATION ABOUT THESE VEHICLES. ACCORDING TO FORD, APPROXIMATELY 234,092 SUBJECT VEHICLES BUILT FROM AUGUST 14, 2000 (?JOB 1?) THROUGH OCTOBER 31, 2001 USED A PARTICULAR ACCELERATOR CABLE KNOWN AS A 16 LAY WIRE DESIGN.THIS DESIGN IS COMPRISED OF THE THROTTLE CABLE SURROUNDED BY A CONDUIT MADE OF SEVERAL CONCENTRIC LAYERS INCLUDING A TEFLON LINER, A NYLON TUBE EXTRUDED OVER THE TEFLON LINER, 16 LAY WIRES WRAPPED AROUND THE NYLON TUBE, AND FINALLY A NYLON JACKET EXTRUDED OVER AND AROUND THE LAY WIRES. FORD REPORTS THAT THROTTLE CONTROL CONCERNS RELATED TO THE ACCELERATOR CABLE ARE LIKELY CAUSED BY A MIGRATION OF THE INNER TEFLON LINER OUT OF THE CONDUIT AT THE DASH PANEL FITTING.SHOULD THE TEFLON LINER MIGRATE OUTWARD SUFFICIENTLY TO CONTACT THE ACCELERATOR PEDAL ARM IT COULD INTERFERE WITH THE PEDAL?S ABILITY TO RETURN TO IDLE.IN NOVEMBER 2001, FORD BEGAN USING A NEW 12 LAY WIRE DESIGN ACCELERATOR CABLE.THIS CHANGE WAS IMPLEMENTED TO ALLOW FOR INSTALLATION OF OPTIONALLY AVAILABLE POWER-ADJUSTABLE PEDALS. FIELD DATA SUGGESTS THAT THE CONDITION WITH THE SUBJECT CABLE IS MORE PREVALENT IN COLD (WINTER) CLIMATES.OF THE 396 WARRANTY CLAIMS RELATED TO THE ALLEGED DEFECT, NEARLY 68% OCCURRED IN WINTER MONTHS AND MOST WARRANTY CLAIMS ARE ASSOCIATED WITH VEHICLES SOLD IN THE NORTHEASTERN, NORTHERN INTERIOR (MIDWEST), AND ROCKY MOUNTAIN REGIONS OF THE UNITED STATES.THIS SEASONAL TREND APPEARS TO BE IN DECLINE WITH FEWER WARRANTY CLAIMS PAID IN WINTER 2005 THAN IN PREVIOUS WINTERS.THERE ARE NO KNOWN CRASHES RELATED TO THE ALLEGED DEFECT ON THE SUBJECT VEHICLES, THE COMPLAINT RATE IS LOW AFTER APPROXIMATELY FOUR YEARS IN SERVICE (3.0 INCIDENTS PER 100,000 VEHICLES) AND THE FAILURE TREND IS DECLINING.THERE HAVE BEEN NO NEW COMPLAINTS SINCE JANUARY 2005.A SAFETY-RELATED DEFECT TREND HAS NOT BEEN IDENTIFIED AT THIS TIME AND FURTHER USE OF AGENCY RESOURCES DOES NOT APPEAR TO BE WARRANTED.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST.ODI WILL CONTINUE TO MONITOR ITS COMPLAINT DATABASE AND WILL RECEIVE UPDATED COMPLAINT AND WARRANTY DATA FROM FORD IN SPRING 2006 TO VERIFY THE TREND ANALYSIS.THE AGENCY WILL TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.

COMPLAINTS REPORT FAILURE OF THE REAR LIFTGATE GLASS SUPPORT WHILE THE OPERATOR IS OPENING OR CLOSING THE GLASS.THE FALLING GLASS CAN STRIKE THE OPERATOR OR BYSTANDER.THE INJURIES REPORTED ARE BRUISES TO THE HEAD, NECK OR BACK, CUTS TO THE FACE, ARM OR HAND.ON SEPTEMBER 9, 2004, FORD NOTIFIED THE AGENCY THAT IT WILL RECALL APPROXIMATELY 955,732 MY 2002 AND 2003 FORD EXPLORER AND MERCURY MOUNTAINEER VEHICLES TO REPLACE THE LIFTGATE GLASS STRUT BRACKETS AND/OR HINGES.SEE NHTSA RECALL 04V442 FOR DETAILS. THIS INVESTIGATION IS CLOSED.

Aftermarket rack and pinion system re-manufactured by Detroit Axel began leaking fluid and caused a loss of power steering within 3 months of purchase. A second unit was installed and after about a year had the exact same failure as the first unit. Also resulting in the loss of power steering. It is my contention that Detroit Axel is not capable of re-manufacturing to a satisfactory safety standard. I believe they should be investigated and perhaps subject to a product recall. I pray nobody has yet been killed by their ineptitude!

NHTSA ID

11562105

Incident

Jan 2, 2023

Body : to much rust, corrosion, on rear of truck other failure or detachment of exterior body like rear gate frame components, and other structural components that may present a safety hazard. Electrical : electrical systems and items such asa wiring and cable on or inside the door, ignition switch cover detach ,instrument panel and gauges blinking that causes motors and actuators that power mechanical devices like (windows, sunroofs, seats, etc.) Generate some kind of electrical problem that may present a safety hazard. Power train :transmissions, transfer cases fluid hard to check ,electronic control units and shift lever inacurated, drive axles, hubs, shafts, differentials, CV joints star vibration that may present a safety hazard.

NHTSA ID

11469915

Incident

Jun 18, 2022

Heard a pop noise under hood. Engine shut off battery light came on. Went to open hood and there was a fire.

NHTSA ID

11463995

Incident

May 10, 2022

TL* THE CONTACT OWNS A 2002 MERCURY MOUNTAINEER. THE CONTACT STATED THAT THE REAR LIFT GATE FAILED TO LATCH SECURELY ON SEVERAL OCCASIONS. THE CONTACT STATED THAT THE FAILURE WAS INTERMITTENT. THE CONTACT STATED ON ONE OCCASION WHILE DRIVING THE VEHICLE, THE LIFT GATE AJAR WARNING LIGHT ILLUMINATED. THE CONTACT'S SON WENT TO CLOSE THE LIFT GATE AND GLASS SHATTERED. THE CONTACT HIRED A GLASS REPAIRMEN TO FIX THE WINDOW FOR $250.00. THE DEALER NOR THE MANUFACTURER HAD BEEN NOTIFIED OF THE FAILURE. UPON INVESTIGATION, THE CONTACT ASSOCIATED NHTSA CAMPAIGN NUMBER: 01I010000 (VISIBILITY) WITH THE FAILURE. THE FAILURE MILEAGE WAS UNKNOWN.

NHTSA ID

11307302

Incident

Jun 1, 2017

TL* THE CONTACT OWNED A 2002 MERCURY MOUNTAINEER. WHILE DRIVING, THE VEHICLE SLID ON ICE. THE CONTACT LOST CONTROL OF THE VEHICLE AND CRASHED INTO A DITCH. THE AIR BAGS FAILED TO DEPLOY. THE CONTACT SUSTAINED HEAD, CHEST, LOWER AND UPPER BACK, ABDOMINAL, AND NECK INJURIES THAT REQUIRED MEDICAL ATTENTION. A POLICE REPORT WAS FILED. THE VEHICLE WAS TOWED TO THE CONTACT'S RESIDENCE. THE VEHICLE WAS NOT TAKEN TO A DEALER OR AN INDEPENDENT MECHANIC FOR DIAGNOSTIC TESTING. THE VEHICLE WAS DESTROYED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 250,000.

NHTSA ID

11184687

Incident

Feb 28, 2019

Mileage

250,000 mi

MY POWER WILL STAY ON FOR LONG PERIODS OF TIME ALSO I'M HAVING AN ACCELERATION PROBLEM WHEN I DRIVE I HAVE TO WAIT FOR IT TO GO TO ABOUT 25 MI TILL 26 FOR IT TO PICK UP ANY SPEED IT TAKES A VERY LONG TIME FOR IT TO PICK UP ANY SPEED IN THE 1ST PLACE.

NHTSA ID

11002611

Incident

Jun 27, 2017

Mileage

25,000 mi

I PURCHASED A VEHICLE ON MARCH 11, 2017 FROM A DEALERSHIP NAMED REDEFINED AUTO SALES IN SKOKIE, IL. SINCE I HAVE PURCHASED THIS VEHICLE, I HAVE SPENT OVER $1,500 IN COSTS FOR REPAIRS TO THIS VEHICLE, BEGINNING WITH I HAD TO GET AN OIL CHANGE ON THE SAME DAY THAT I PURCHASED THE VEHICLE BECAUSE THE CHANGE OIL REQUIRED LIGHT CAME ON AS SOON AS I EXITED THE EXPRESSWAY IN ROUTE FROM THE DEALERSHIP. ALSO, AS I WAS EN ROUTE FROM THE DEALERSHIP, ON THE EXPRESSWAY A MOTORIST TRIED TO CUT ME OFF AND THAT IS WHEN I FOUND OUT THAT THE HORN WAS NOT WORKING. THINGS HAVE JUST WENT DOWNHILL FROM THERE.

NHTSA ID

10993134

Incident

Mar 11, 2017

I PURCHASED A USED VEHICLE FROM REDEFINED AUTO SALES LOCATED IN SKOKIE, IL ON 3/11/17. SINCE THEN I HAVE SPENT OVER $1500.00 IN COST FOR REPAIRS ON THIS VEHICLE, BEGINNING WITH I HAD TO GET THE OIL CHANGED THE SAME DAY THAT I BOUGHT THE VEHICLE BECAUSE THE CHANGE OIL REQUIRED LIGHT CAME ON AS SOON AS I EXITED THE EXPRESSWAY, I ALMOST GOT INTO A SERIOUS ACCIDENT ON THE EXPRESSWAY IN ROUTE FROM THE CAR DEALERSHIP BECAUSE A MOTORIST TRIED TO CUT ME OFF AND THAT IS WHEN I DISCOVERED THAT THE HORN WAS NOT WORKING. THE NEXT DAY THE POWER DOOR LOCKS STOPPED WORKING AND THINGS JUST HAS WENT DOWN HILL SINCE THEN, THE VEHICLE IS IN THE SHOP RIGHT NOW AS I'M TYPING THIS, I HAVE NOT DRIVEN THE VEHICLE ANYWHERE OTHER THAN BACK AND FORTH TO REPAIR SHOPS. I FILED A COMPLAINT WITH THE BBB BUT NOTHING WAS DONE ABOUT THE COMPLAINT BECAUSE THE BUSINESS RESPONDED SAYING THE VEHICLE WAS USED AND I REJECTED THE RESPONSE AND THEN RECEIVED AN EMAIL FROM THE BBB SAYING THAT THE CASE WAS CLOSED. THIS VEHICLE WAS A LEMON WITH A LOT OF ISSUES AND NONE OF THOSE ISSUES WERE DISCLOSED TO ME WHEN I PURCHASED THE VEHICLE.

NHTSA ID

10991755

Incident

Mar 11, 2017

Some 2000 and newer Ford, Lincoln and Mercury vehicles equipped with aluminum body panels may exhibit corrosion concerns appearing as bubbled and/or peeling paint with or without accompanying white dust. Panel replacement is recommended. Follow the Service Procedure steps to correct the condition

Some 2000 and newer Ford, Lincoln and Mercury vehicles equipped with aluminum body panels may exhibit corrosion concerns appearing as bubbled and/or peeling paint with or without accompanying white dust. Panel replacement is recommended. Follow the Service Procedure steps to correct the condition

FORD: SOME VEHICLES MAY EXHIBIT OIL SEPARATION FROM THE INTERNAL LUBE FOUND IN THE UNITIZED CARTRIDGE SEAL. OIL SEPARATION APPEARS TO BE AND IS OFTEN MISDIAGNOSED, AS AN AXLE LUBE LEAK. *PE

SOME 1997-2008 VEHICLES EQUIPPED WITH A 4.6L 2V, 5.4L 2V, OR 6.8L 2V ENGINE--SPARK PLUG THREAD REPAIR PROCEDURE--NOT COVERED UNDER NEW VEHICLE LIMITED WARRANTY. *NJ THIS INCLUDES F-53 MOTORHOME CHASSIS. UPDATED 2/23/10. *PE

MALFUNCTION INDICATOR LAMP ON WITH PCM DIAGNOSTIC TROUBLE CODE P0463 AND/OR IC DIAGNOSTIC TROUBLE CODE B1201 - FUEL GAUGE DROPS TO EMPTY OR SLOW TO UPDATE AFTER REFUELING. *TT

LIMITED SLIP AXLE CHATTER, SHUDDER, BINDING SENSATION, OR VIBRATION DURING LOW SPEED TURNING MANEUVERS. *TT