2002 Mercury Sable

On June 21, 2013, Ford initiated Customer Satisfaction Program 13B04 to address a concern with Speed Control Cable damage in certain model year (MY) 2000 through 2003 Taurus and Sable vehicles equipped with 3.0L 4V Duratec engines and built at the Chicago assembly plant.In the dealer letter for the program, Ford indicates that the Speed Control Cables on affected vehicles may be susceptible to damage or becoming partially disconnected during under hood vehicle maintenance (e.g., replacing a battery or changing the air filter) and that a damaged Speed Control Cable could interfere with the throttle's full return to idle when the accelerator pedal is released.Ford's program instructs dealers to inspect the Speed Control Cables and replace any with any portion of either collar retention tab missing.Dealers will install a Collar Reinforcement Clip at the Speed Control Cable collar in all vehicles. Figure 1 shows the location of the Speed Control Cable in the engine compartment and the proximity of the battery and air filter.The failure mode of the cable assembly is associated with the plastic collar used to secure the cable to a bracket near the throttle body (Figure 2).Damage to one or both retention tabs used to secure the cable ferrule within the collar may allow the ferrule to become disconnected from the collar when the throttle is opened during accelerator pedal application.Additional examples of Speed Control Cables with damaged collar retention tabs and partial ferrule displacement are shown in Figures 3 through 5.If the displacement pulls the ferrule completely out of the collar, the ferrule end may contact the face of the collar when the accelerator pedal is released and the throttle is returning to idle (Figure 6).This results in a throttle stuck at approximately 26-29% open.Testing conducted at NHTSA's Vehicle Research and Test Center found that brake booster vacuum may become depleted, resulting in reduced brake effectiveness, if the brake is applied repeatedly when the throttle is stuck at this position.Drivers who experienced this condition have reported being surprised that the engine speed did not drop as expected and in some cases misjudged the degree of braking required to slow the vehicle.Some drivers reported difficulty in braking the vehicle and responded by shifting to neutral or turning the engine off.One minor crash occurred when the vehicle contacted a roadside fence post after the driver responded to the stuck throttle by shifting the car to neutral, turning the engine off and coasting to the side of a roadway with no shoulder, resulting in approximately $400 damage to the vehicle.There were four crashes reported which were attributed to increased stopping distance caused by the increased engine power and/or reduced brake effectiveness, including two of the complaints to ODI.In one crash reported to ODI (VOQ 10516101), the subject vehicle allegedly hit the back end of a truck at approximately 40 mph causing about $2000 damage.In the other crash complaint to ODI (VOQ 10501834), the subject vehicle side-swiped a vehicle as the driver was unable to stop in time and attempted to maneuver around a line of vehicles stopped at a traffic light.When the tow truck driver subsequently started the incident vehicle, the engine was still racing and it was verified that the Speed Control Cable ferrule was stuck on the collar.After further investigation, ODI does not consider the crashes reported in VOQs 10456249 and 10159399 to be related to the Speed Control Cable problem.

To date, ODI is aware of 2,401 non-duplicative complaints related to the alleged defect. In addition, ODI is aware of 1,411 subject vehicles with one or more warranty claims related to the alleged defect. In total, ODI is aware of 3,645 unique subject vehicles that have experienced one or more front suspension coil spring fractures. ODI is also aware of four minor crashes related to the alleged defect resulting in one minor injury.With greater than eight years of exposure, a large subject vehicle population and approximately 2,052 reported front tire punctures caused by fractured coil springs (at all speeds), there have been no reported severe crashes, deaths or injuries related to the alleged defect. The real world consequences of these defective coil springs have been a small number of minor control problems that resulted in minor damage; suggesting that the effect of the defect on vehicle control is minor.A safety-related defect 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. The agency will continue to monitor this issue and will take further action if warranted by the circumstances. See the EA08-018 Engineering Analysis Closing Report for more details.

MS. RODMAN REPORTED THAT AFTER HER VEHICLE WAS INSPECTED FOR THE RECALL, HER MOTHER EXPERIENCED A SUDDEN ACCELERATION AND CRASHED THE SABLE INTO A LIGHT POLE.PREVIOUSLY NHTSA HAD CONDUCTED AN INVESTIGATION FOR THIS ISSUE (PE02-035) THAT RESULTED IN THE RECALL (02V-266) OF 369,000 MY 2000-2002 TAURUS AND SABLE VEHICLES EQUIPPED WITH ADJUSTABLE BRAKE AND ACCELERATOR PEDALS TO INSURE THAT THE SEPARATION BETWEEN THE PEDALS WAS AT LEAST 50MM..A REVIEW OF ODI'S DATABASE FOR COMPLAINTS REGARDING RECALL 02V-266 DID NOT IDENTIFY ANY RECALL REMEDY COMPLAINTS OTHER THAN THE PETITIONER'S.MS. RODMAN?S VEHICLE WAS INSPECTED BY ODI USING FORD?S SPECIAL TOOL AND HER VEHICLE WAS FOUND TO EXCEED 50MM.ALSO, THE LATERAL MOVEMENT OF THE PEDALS WAS FOUND NOT TO BE EXCESSIVE RELATIVE TO OTHER COMPARABLE TAURUS AND SABLE VEHICLES.THEREFORE, IT IS UNLIKELY THAT NHTSA WOULD ISSUE AN ORDER REQUIRING FORD TO PROVIDE A DIFFERENT REMEDY FOR THIS DEFECT.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.FOR ADDITIONAL INFORMATION CONCERNING THIS ANALYSIS, PLEASE REFER TO THE FEDERAL REGISTER NOTICE DATED MARCH 23, 2004 (VOL 69, NO 56, PAGES 13619-13620).

FORD CONDUCTED A RECALL IN MARCH, 2001 TO CORRECT A DEFECT AFFECTING THE BRAKE LIGHT SWITCH IN MY 2000 THROUGH EARLY-2001 TAURUS AND SABLE VEHICLES EQUIPPED WITH POWER ADJUSTABLE PEDALS (RECALL 01V-078).RQ03-008 WAS OPENED TO INVESTIGATE COMPLAINTS CONCERNING THE REMEDY AND SCOPE OF 01V-078.ODI'S ANALYSIS IDENTIFIED CONCERNS WITH POST-REPAIR FAILURES IN RECALLED VEHICLES,FAILURES IN MY 2001-02 VEHICLES WITH ADJUSTABLE PEDALS THAT WERE NOT INCLUDED IN RECALL 01V-078, AND FAILURES IN MY 2000 VEHICLES WITH FIXED PEDALS.(NOTE: THE MANUFACTURER FAILURE DATA IN THIS RESUME INCLUDES ALL CRASHES AND INJURIES, BUT THE COMPLAINT INFORMATION IS LIMITED TO MY 2001-02 VEHICLES THAT WERE NOT INCLUDED IN THE SCOPE OF RECALL 01V-078.)ON MARCH 1, 2004, FORD NOTIFIED NHTSA OF A SAFETY DEFECT IN MY 2000 THROUGH EARLY-2003 TAURUS AND SABLE VEHICLES EQUIPPED WITH ADJUSTABLE PEDALS AND MY 2000 SUBJECT VEHICLES EQUIPPED WITH FIXED PEDALS (RECALL 04V-106).THE NOTIFICATION IDENTIFIED THREE FACTORS CONTRIBUTING TO BRAKE LIGHT CIRCUIT FAILURES:(1) CONTINUING GREASE CONTAMINATION ISSUES THAT PROMPTED 01V-078; (2) MISALIGNMENT OF THE BOOSTER ROD PIN AND THE BRAKE LIGHT SWITCH; AND (3) WIRE ASSEMBLY FATIGUE.THE FIRST TWO CONDITIONS WERE LIMITED TO VEHICLES WITH ADJUSTABLE PEDALS AND THE LATTER CONDITION AFFECTED VEHICLES WITH FIXED PEDALS.FORD WILL INSTRUCT OWNERS TO BRING THEIR VEHICLES TO A DEALER TO HAVE THE BRAKE LIGHT SWITCH AND ASSOCIATED WIRING REPLACED WITH A RE-DESIGNED BRAKE LIGHT SWITCH AND WIRING ASSEMBLY.

10/2/2022 was on I 94 east bound lost momentum rpms jump to 6k then lost all gears in transmission car has 88639 miles on it hardly driven changed trans fluid hoping to get trans working again and still won't move in any gear had to wait 4 hours on freeway for a tow just to get it off the freeway had to fight with AAA for the 4 hours to get it towed now in my driveway and still won't move at all

NHTSA ID

11487805

Incident

Oct 2, 2022

The contact owns a 2002 Mercury Sable. The contact stated that while operating the vehicle, the check engine warning light and transmission symbol remained illuminated. Additionally, while driving at various speeds, the vehicle would not properly accelerate. The contact stated that the vehicle shuddered and stalled occasionally. The cause of the failure was not yet determined. The local dealer and manufacturer were notified of the failure but no assistance was offered. The failure mileage was unknown.

NHTSA ID

11487204

Incident

Nov 1, 2018

The contact owns a 2002 Mercury Sable. The contact stated while attempting to shift the vehicle out of park, the gear shifter failed to move out park. The contact stated no warning light was illuminated. The vehicle was taken into a local mechanic where it was not diagnosed or repaired. Upon investigation, the contact associated the failure with NHTSA Campaign Number: 04V106000 (Exterior Lighting) however, the VIN was not included. The manufacturer was informed of the failure and informed the contact that the VIN was not under recall. The failure mileage was approximately 130,000.

NHTSA ID

11438044

Incident

May 10, 2021

Mileage

130,000 mi

TL* THE CONTACT OWNS A 2002 MERCURY SABLE. THE CONTACT STATED THAT WHILE REVERSING OUT OF THE DRIVEWAY, THE FRONT DRIVER'S SIDE TIRE EXPLODED. THE SUSPENSION COIL SPRING ON THE DRIVER'S SIDE FRACTURED AND SLASHED THE TIRE CAUSING THE TIRE TO EXPLODE. THE CONTACT STATED THAT THE SUSPENSION NEEDED TO BE REPLACED. THE VEHICLE WAS TOWED TO AN INDEPENDENT MECHANIC BUT WAS NOT DIAGNOSED NOR REPAIRED. NEITHER THE DEALER NOR THE MANUFACTURER WERE MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 37,500.

NHTSA ID

11361053

Incident

Sep 24, 2020

Mileage

37,500 mi

CAR FIRE DUE TO RECALLED FUSES HAD THIS CAR FOR 5 YEARS AND HAD NO ISSUES

NHTSA ID

11102972

Incident

Mar 8, 2018

Mileage

177,000 mi

AUTOMATIC HEADLIGHTS RELAY SODDARD INTO BACKSIDE OF FUSE PANEL (GEM) WAS BAD LOCATION FOR A PERSON WITH NO EXPERIENCE TO FIX OR LOCATE MOST PEOPLE NEVER GOT IT FIXED BECAUSE OF NO EXPERIENCE AND AMOUNT OF MONEY TO HAVE AN ELECTRICAL MECHANIC TO FIX. I UNDERSTAND THERE WAS A FEW PEOPLE DID GET IT FIXED THROUGH A RECALL BUT I DIDN'T AND I NEVER GOT A RECALL FOR THIS IN THE MAIL. I WOULD LIKE FORD MOTOR COMPANY FIX THIS BECAUSE I WAS NEVER NOTIFIED OF THIS PROBLEM. MY CAR HAS HAD THIS PROBLEM FOR ABOUT 12 YEARS.

NHTSA ID

11100705

Incident

Jan 1, 2010

Mileage

35,000 mi

DRIVING(IN MOTION) ON BUSY ROAD(CITY STREET) NEAR HOME, ACCELERATED TO 45MPH, TRIED TO SLOW DOWN FOR LIGHT, REMOVED FOOT OFF GAS AND CAR DID NOT SLOW. HAD TO SLAM ON BRAKES IN ORDER TO AVOID CAR STOPPED AT LIGHT. TOOK ALL MY STRENGTH ON BRAKE TO KEEP CAR STOPPED. PUT IN NEUTRAL, NO CHANGE. PUT IN PARK NO CHANGE,STILL 4000 RPMS. WANTED TO GET VEHICLE HOME SO I PUT ON FLASHERS DROVE HOME WHILE APPLYING BRAKES.I WAS SCARED TO DEATH. SHOULD HAVE PULLED OVER AND TURNED CAR OFF BUT WANTED TO GET IT HOME SO I COULD AVOID A TOW. I AM PRETTY HANDY AND AM DOING RESEARCH IN ORDER TO FIX MYSELF.POPPED THE HOOD AT HOME AND IMMEDIATELY SAW THAT THE CABLE GOING TO THE THROTTLE BODY WAS BROKEN AND HUNG UP ON A CLIP ON THE LINKAGE COVER. IMAGE IS OF ANOTHER VEHICLE WITH THE SAME EXACT PROBLEM.

NHTSA ID

10990855

Incident

May 21, 2017

Mileage

101,000 mi

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

NHTSA ID

10981455

Incident

Apr 24, 2017

Mileage

189,000 mi

This article supersedes TSB 19-2026 to update the vehicle model years affected. Some 2000 and newer Ford/Lincoln/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.

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: SEE DOCUMENT SEARCH BUTTON FOR OWNER LETTER. SPEED CONTROL CABLE IS SUSCEPTIBLE TO DAMAGE AND CAN DISCONNECT DURING HOOD MAINTENANCE AND ALSO INTERFERE WITH FULL THROTTLE RETURN TO IDLE AFTER RELEASING ACCELERATOR PEDAL. MODELS 2000-2003 TAURUS, SABLE. *PE

CAMSHAFT TICK NOISE - 3.0L 4V ENGINE ONLY. *TT

POWER WINDOW CONCERNS - SERVICE TIP. *TT