1996 Mercury Villager TSBs

ENGINE OIL SYSTEM PRIMING PROCEDURES, SERVICE TIPS FOR REPORTS OF PREMATURE ENGINE FAILURE.

SOME ENGINE ASSEMBLIES WITH ALUMINUM CYLINDER HEADS REPAIRED IN-VEHILE HAVE BEEN FOUND TO LEAK COOLANT AND/OR OIL FROM THE CYLINDER HEAD GASKET AREA.

SOME VEHICLES MAY DISPLAY DIAGNOSTIC TROUBLE CODE 34, OR P0325 (MIL DTC 0304) WHEN TESTING THE ELECTRONIC ENGINE CONTROL SYSTEM.

SOME VEHICLES MAY DISPLAY DIAGNOSTIC TROUBLE CODE (DTC) 34, OR PO325 (MIL DTC 0304) WHEN TESTING THE ELECTRONIC ENGINE...

THIS BULLETIN MENTIONS THE TWO DIFFERENT CYLINDERS AVAILABLE FOR REPLACEMENT LIFTGATE SUPPORT CYLINDERS.

ON SOME VEHICLES THE CHECK ENGINE WARNING LAMP MAY ILLUMINATE AND DIAGNOSTIC TROUBLE CODES 32, 35, P0400, P0402, P1400,...

FORD MOTOR COMPANY HAS RELEASED A PRIVATE LABELED MATERIAL TO BE USED FOR IRON PARTICLE / ACID RAIN SERVICE REPAIRS.

FORD MOTOR COMPANY NOW RECOMMENDS SAE 5W-30 VISCOSITY GRADE FOR SERVICING ANY FORD GASOLINE-POWERED VEHICLE REGARDLESS OF MODEL YEAR.

INFORMATION REGARDING EXHAUST GAS RECIRCULATION VALVE (EGR) SYSTEM DIAGNOSIS.

VEHICLES EXHIBITING A "SQUEAKING" OR "CHIRPING" FROM THE BLOWER MOTOR AT LOW BLOWER MOTOR SPEEDS.

ENGINEERING IS INVESTIGATING DTC'S 1103, 1104, 1105 ON A FEW 1996 AND 1997 VILLAGERS - DURING CODE RETRIEVAL A TP...

BLOWER MOTOR- "CHIRPING" OR "SQUEAKING" FROM BLOWER MOTOR AT LOW SPEEDS.

TRANSMISSION SHIFT LEVER DIFFICULT TO MOVE FROM THE PARK POSITION DUE TO IGNITION SWITCH CYLINDER PLUNGER SHIFT ROD BEING OUT OF ALIGNMENT.

POOR HEATER CAPABILITY IN VILLAGERS DURING COLD WEATHER WHILE THE ENGINE IS AT IDLE.

A MIL CONCERN DTC 0208 ON VEHICLES, WHICH INDICATES AN ERRONEOUS CYLINDER CODE.

POOR HEATER CAPABILITY IN VEHICLES DURING COLD WEATHER WHILE THE ENGINE IS AT IDLE.

A RESOLUTION FOR ERATIC AND/OR HARSH UPSHIFT- THE ROOT CAUSE IS MICRO PARTICLE DEBRIS IN THE TRANSMISSION VALVE BODY.

VILLAGERS MAY DEVELOP AN INOPERATIVE REAR WIPER MOTOR.

CHECK ENGINE LIGHT, CODE P030X, WITH NO DRIVEABILITY COMPLAINT.

VEHICLES MAY DEVELOP AN INOP REAR WIPER MOTOR.

PROCEDURE FOR INTERMITTENT ENGINE FLARE ON STARTUP FROM A STOP.

CONCERN OF ENGINE FLARE DURING 2-3 SHIFT.

MAY EXHIBIT A GRINDING/SQUEALING NOISE FROM THE REAR BRAKES.

BRAKE SHIFT INTERLOCK.*JB

INFORMATION REGARDING TRANSMISSION FLUID USAGE CHARTS.

INFORMATION ON SERVICING THE FORWARD CLUTCH.

INFORMATION REGARDING THE SERVICING OF THE FORWARD CLUTCH, WHICH HAS BEEN REPLACED BY THREE INDIVIDUAL PARTS.

BE AWARE THAT THE F6XZ-7A360-AA FORWARD CLUTCH ASSEMBLY HAS BEEN REPLACED BY 3 INDIVIDUAL PARTS.

INFORMATION REGARDING THE NEW TRANSMISSION COOLER FLUSHER- SERVICE TIP.

WHINING NOISE FROM TRANSAXLE ON LIGHT ACCELERATION, TIP-IN ACCELERATION BETWEEN 40-64 KM/H (25-40 MPH)

CONDITIONS WITH THE BRAKE LAMPS INADVERTENTLY DISABLING THE BRAKE SHIFT INTERLOCK.

INFORMATION ON A NEW TRANSMISSION FLUID USAGE CHART.

FLUID- TRANSMISSION FLUID USAGE CHARTS.

TRANSAXLE- DIFFICULTY MOVING SHIFT LEVER FROM "PARK" POSITION- VEHICLES BUILT THROUGH 2/1/97.

INTERMITTENT TRANSMISSION SHIFT LEVER THAT IS DIFFICULT TO MOVE FROM THE PARK POSITION.

VEHICLES MAY EXPERIENCE A TRANSMISSION OVERDRIVE WHINE.

A RESOLUTION FOR ERRATIC AND/OR HARSH UPSHIFT.

TRANSAXLE - TORQUE CONVERTER REPLACEMENT GUIDELINES AND TORQUE CONVERTER/TRANSAXLE COOLING SYSTEM CLEANING PROCEDURES - SERVICE TIP.

TORQUE CONVERTER - LEAK TEST PROCEDURE - SERVICE TIP.

VEHICLES MAY EXPERIENCE UNEXPLAINED MIL LIGHT CODES &/OR IRREGULAR SHIFTING (A4LD).

FUEL PUMP IMPROVED, HARDENED INNER GEROTOR GEAR.

IMPROVED FUEL PUMP W/ AN IMPROVED, HARDENED INNER GEROTOR GEAR.

LAMP-BRAKE-INVADVERTENT DISABLING OF BRAKE SHIFT INTERLOCK.

NEW TRANSMISSION COOLER FLUSHER - SERVICE TIPS.

EXPERIENCING A SQUEALING OR GRINDING NOISE FROM EITHER THE FRONT OR REAR BRAKES WHEN THE CUSTOMER LIGHTLY APPLIES THE BRAKES.

REAR BRAKES ARE BINDING OR OVERHEATING AFTER HAVING BEEN SERVICED.

INFORMATION FOR SERVICING AND DIAGNOSING BRAKE VIBRATION, BRAKE INSPECTION, AND BRAKE FRICTION MATERIAL REPLACEMENT.

SOME VEHICLES MAY EXHIBIT AN ILLUMINATED ANTI-LOCK BRAKE SYSTEM (ABS) WARNING LAMP AND TROUBLE CODES 41/45/55/63.

SOME VEHICLES MAY EXHIBIT AN INTERMITTENT ABS WARNING LAMP CONCERN AND TROUBLE CODES 41/ 45/ 55/ 63 MAY BE RETRIEVED DURING A QUICK TEST.

SUBJECT REGARDING THE AVAILABILITY OF HUB-MOUNT BRAKE ROTOR MACHINING EQUIPMENT.

AVAILABILITY OF HUB-MOUNT BRAKE ROTOR MACHINING EQUIPMENT.

THE USE OF PETROLEUM-BASED GREASE AS A LUBRICANT IN SERVICING DISC BRAKES IS NO LONGER ACCEPTABLE.

SERVICE TIP INFORMATION REGARDING ELIMINATION OF SANDING ROTORS AND DRUMS.

HUB-MOUNT BRAKE ROTOR MACHINING EQUIPMENT FROM ROTUNDA IS NOW APPROVED FOR WARRANTY AND SERVICE USE.

INSTRUCTIONS ON HOW TO MANUALLY CLEAR CODES FROM MEMORY AFTER AN ABS BRAKE REPAIR.

DIAGNOSIS OF ABS SYSTEM.

DIAGNOSIS OF A VILLAGER ABS SYSTEM.

ABS SYSTEM AND PRIOR TO REPLACEMENT OF THE HYDRAULIC ANTI-LOCK ACTUATOR ASSEMBLY.

INTERMITTENT ABS LAMP ON AND WHEEL SENSOR DTC'S SET WHILE DRIVEING THE VEHICLE ON THE HIGHWAY.

BRAKES - ELIMINATION OF SANDING ROTORS AND DRUMS - SERVICE TIP.

CONCERNS OF ABS AMBER INDICATOR LIGHT ON.

IMPROVED REAR SHOCK ABSORBERS AVAILABLE.

THE USE OF PETROLEUM-BASED GREASE AS A LUBRICANT IN SERVICING DISC BRAKES IS NO LONGER ACCEPTABLE BECAUSE IT MAY BE...

SOME VEHICLES WITH ANALOG INSTRUMENT CLUSTERS MAY EXHIBIT A CONCERN OF A FLUCTUATING OR JUMPING TACHOMETER INDICATOR NEEDLE.

SOME VEHICLES WITH ANALOG INSTRUMENT CLUSTERS MAY EXHIBIT A CONCERN OF A FLUCTUATING OR JUMPING TACHOMETER INDICATOR NEEDLE.

SOME VEHICLES MAY EXHIBIT A SULFUR ODOR DURING VARIOUS DRIVING CONDITIONS.

ADDRESSING AN INTERMITTENT CONDITION WHERE THE SPEED CONTROL WILL NOT SET OR MAY DISENGAGE WHILE DRIVING.

EXHIBITING AN INTERMITTENT CONDITION WHERE THE SPEED CONTROL WILL NOT SET OR MAY DISENGAGE WHILE DRIVING.

INFORMATION DESIGNED TO AID IN THE DIAGNOSIS, TESTING AND REPAIR OF NOISE, VIBRATION AND HARSHNESS (NVH) CONCERNS.

SOME VEHICLES MAY EXHIBIT A SULFUR ODOR DURING VARIOUS DRIVING CONDITIONS.

SHEET METAL DISTORTION AROUND THE AREA OF THE REAR WIPER SHAFT.

REPAIR INSTRUCTIONS FOR DTC P0705.

SAFETY BELT- RESTRICTION OF MOVEMENT WHILE DRIVING- VEHICLES WITH SECOND ROW BENCH SEAT, RIGHT SIDE- VEHICLES BUILT THROUGH 1/2/97.

SAFETY BELTS- THIRD ROW SEAT- BROKEN GUIDE MOUNTED ON RIGHT SIDE OF SEAT- VEHICLES BUILT FROM 9/18/95 THROUGH 11/1/96.

SQUEAK/RUB NOISE WHEN TURNING.

WINDNOISE AT THE UPPER B-PILLAR CORNER AREA.

EXTENDED CRANK - LONG CRANK TIME DURING MORNING START-UPS - VEHICLES BUILT THROUGH 7/1/96 NO START - NO START AFTER...

EXTENDED CRANK OR INTERMITTENT STALLING IN HIGH AMBIENT TEMPERATURES.

PARTS INFORMATION FOR REPLACING THE MAIN CONTROL.

REVISED HOSE PART# F6HZ-9J291-A HAS BEEN DEVELOPED TO REPLACE HOSE THAT SHOWS SIGNS OF DETERIORATION, CRACKS MAY APPEAR...

FOR MIL ON W/ DTC 0802 &/OR 0905 CHECK CONNECTOR C198.

THIS ARITLCE IS TO PROVIDE INFORMATION ON REPLACEMENT OF OLD STYLE HOOD LAMP SWITCH TO THE RVISED MECHANICAL HOOD LAMP SWITCH.

THERE MAY BE A SQUEAK / RATTLE NOISE FROM THE SLIDING DOOR AREA AND / OR THE SLIDING DOOR MAY BE DIFFICULT TO CLOSE.

REPEAT MESSAGE REGARDING POWER DOOR LOCKS SELF-LOCKING / ERRATIC OPERATION.

SOME 1996-1998 VILLAGERS EXHIBIT INTERMITTENT SELF-ACTIVATION OF POWER DOOR LOCKS.

SOME 1996-1998 VILLAGERS EXHIBIT INTERMITTENT SELF-ACTIVATION OF POWER DOOR LOCKS.

SUBJECT REGARDING DOOR TRIM PANEL REPLACEMENT - SERVICE TIP.

INTERMITTENT SELF-ACTIVATION OF THE POWER DOOR LOCKS MAY OCCUR ON SOME VEHICLES.

INTERMITTENT SELF-ACTIVATION OF THE POWER DOOR LOCKS MAY OCCUR ON SOME VEHICLES.

INTERMITTENT SELF-ACTIVATION OF THE POWER DOOR LOCKS MAY OCCUR ON SOME VEHICLES.

FRONT DOOR WINDOW BINDING WHILE TRAVELING UP OR DOWN.

POWER DOOR LOCK - INTERMITTENT POWER DOOR LOCK OPERATION.

A "HISSING" NOISE SOUNDING LIKE A WINDOW IS SLIGHTLY OPEN, FROM THE UPPER B-PILLAR AREA ON THE DRIVER'S SIDE, MAY OCCUR...

WIND NOISE AT THE UPPER B-PILLAR CORNER AREA ON 1996 AND 1997 VILLAGERS MAY BE CAUSED BY THE DOOR WINDOW RUN RUBBER NOT FITTING TIGHT ENOUGH.

VEHICLE EXHIBITING AN INTERMITTENT ACTIVATION OF THE POWER DOOR LOCKS.

INTERMITTENT ACTIVATION OF POWER DOOR LOCKS.

INTERMITTENT POWER DOOR LOCK ACTIVATION.

VEHICLE MAY EXPERIENCE AN INTERMITTENT ACTIVATION OF THE POWER DOOR LOCKS.

ON SOME VEHICLES, THE AIR BAG INDICATOR LAMP MAY FLASH CONSTANTLY.

SOME VEHICLES MAY EXHIBIT A FLASHING AIR BAG WARNING LAMP INDICATING A FAULT IN THE SYSTEM.

SUBJECT REGARDING AIR BAG SYSTEM DIAGNOSIS.

LAMP- AIR BAG WARNING LAMP FLASHES ALL THE TIME OR INTERMITTENTLY- NO CODES STORED IN MEMORY.

2ND ROW BENCH SEAT, MAY EXPERIENCE A RIGHT SIDE SEAT BELT THAT MAY ENTER THE AUTOMATIC LOCKING MODE PREVENTING FREEDOM OF MOVEMENT WHILE DRIVING.

RIGHT SIDE SEAT BELT ON VEHICLES EQUIPPED WITH 2ND ROW BENCH SEAT MAY ENTER THE AUTOMATIC LOCKING MODE.

VILLAGERS EQUIPPED WITH A 2ND ROW BENCH SEAT, MAY EXPERIENCE A RIGHT SIDE SEAT BELT THAT MAY ENTER THE AUTOMATIC LOCKING MODE.

PLASTIC SEAT BELT GUIDE ON 2ND ROW SEAT WILL BREAK IF USED TO RAISE THE SEAT BACK FROM A LOWERED POSITION.

SUBJECT ON A WIRE HARNESS TERMINAL REPAIR KIT AVAILABLE FOR REPAIRING ELECTRICAL WIRING HARNESSES.

WHEN ATTEMPTING TO INTERFACE WITH VILLAGER PCM/TCM ON 1996 & 1997 VEHICLES, USE THE OBD II DLC CONNECTOR LOCATED JUST BENEATH THE STEERING COLUMN.

INTERFACE WITH THE VILLAGER PCM/TCM ON VEHICLES, USE THE OBD II DLC CONNECTOR LOCATED JUST BENEATH THE THE STEERING COLUMN.

MASS AIR FLOW SENSOR - REPLACEMENT AS AN ASSEMBLY - SERVICE TIP.

DAMAGE TO FRONT AND/OR REAR 02 SENSORS FOR 96-97 VILLAGERS.

DTC P0135/P0141 MAY BE SET WHEN THE PCM RECEIVES INACCURATE VOLTAGE FROM THE 02 HEATER CIRCUIT.

FOR CONCERNS OF STALLING, REFLASH PCM W/ 1996 CALIBRATION (R11 LEVEL).

SOME VEHICLES MAY EXHIBIT HEATER CORE LEAKS.

INFORMATION ON IDENTIFYING NON-APPROVED / ALTERNATE REFRIGERANTS WHICH COULD CAUSE SAFETY, AND PERFORMANCE CONCERNS IF INSTALLED IN FORD A/C SYSTEMS.

SERVICE INFORMATION FOR MUSTY AND MILDEW TYPE ODORS COMING FROM THE AIR CONDITIONING / HEATING SYSTEM.

EXPERIENCING LOW OR NO A/C PERFORMANCE IN HIGH AMBIENT TEMPERATURES.

AIR CONDITIONING - COMPRESSOR FAILURE - INSUFFICIENT AMOUNT OF REFRIGERANT OIL.

CLIMATE CONTROL A/C SERVICE TECH TIPS.

SOME VEHICLES MAY PRODUCE AN OBJECTIONABLE SULFUR OR ROTTEN EGG - TYPE ODOR FROM THE EXHAUST DURING VARIOUS DRIVING CONDITIONS.

CONCERNS WITH EGR FLOW MALFUNCTION.

BRIEF INFORMATION REGARDING EXHAUST GAS RECIRCULATION (EGR) SYSTEM DIAGNOSIS.

EXPERIENCING A WHINE / BUZZ TYPE NOISE IN THE SPEAKERS OF THE ENTERTAINMENT RADIO OR TWO-WAY RADIO ON VEHICLES WITH AN IN-TANK ELECTRIC FUEL PUMP.

EGR FUNCTION TESTING.

FUEL ECONOMY- CUSTOMER EXPECTATIONS VERSUS VEHICLE USAGE.

EXPERIENCING A CRUNCH / GRUNT NOISE FROM THE REAR SUSPENSION OF SOME VEHICLES.

A CHUNCH/GRUNT NOISE COMING FROM THE REAR LEAF SPRING SHACKLE BUSHING MAY BE REPAIRED BY INSTALLING AN IMPROVED SHACKLE...

CHUNCH/GRUNT NOISE COMING FROM THE REAR LEAF SPRING SHACKLE BUSHING MAY BE REPAIRED BY INSTALLING AN IMPROVED SHACKLE ASSEMBLY.

MALFUNCTION INDICATOR LAMP ILLUMINATED WITH DIAGNOSTIC TROUBLE CODES (DTCS) P0120, P0510,P0731,P0732 AND/OR P0733 STORED...

SOME VEHICLES MAY EXHIBIT A MALFUNCTION INDICATOR LAMP (MIL) ON AND DIAGNOSTIC TROUBLE CODE ( DTC ) 32.

INFORMATION FOR WHEN DIAGNOSING CONCERNS W/ FACTORY INSTALLED CELLULAR PHONES.

SOME VEHICLES EQUIPPED WITH COMPACT DISC CHANGER MAY EXHIBIT A 6 DISC CD CHANGER THAT IS NOT EJECTING THE MAGAZINE OR IS...

ELECTRONIC TEMPERATURE CONTROL DISPLAY- DISPLAYS FAHRENHEIT AND CELSIUS IN DIFFERENT DISPLAYS- VEHICLES EQUIPPED WITH ELECTRONIC TEMPERATURE CONTROL.

INTERIOR- LEATHER SEAT CLEANING PROCEDURE- SERVICE TIP.

LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - SERVICE TIP.

INFORMATION ON TIRE COMPANY TELEPHONE NUMBERS FOR CUSTOMER ASSISTANCE.

STEERING WHEEL SWITCHES- INTERMITTENT OPERATION OF RADIO AND/OR SPEED CONTROL- VEHICLES BUILT THROUGH 12/1/96.