Engine
4.0L 6-cyl
How to read this file. Complaint records are unverified owner submissions to the federal safety agency. Counts are raw, not adjusted for sales volume or vehicle age. Recall campaigns apply to the model; only a VIN check shows whether this car is affected or repaired. Parts shown are named by an editorial note or listed as a search directory; none is a diagnosis. Full methodology.
Fault profile
Complaint-component records on this vehicle, grouped by family. A complaint naming two systems counts once in each.
Complaints are owner-reported and not verified by the agency.
When it fails
The timing of this vehicle's reported failures, from the complaint file itself. A cluster tells you what to expect and when; it is shaped by reporting behavior as well as by the vehicle.
Vehicle age when the failure occurred
Years between the model year and the owner's reported failure date. Based on 364 of 372 complaints with a usable failure date.
Odometer when the failure occurred
Owner-reported mileage at failure, in 20,000-mile bands. Based on 257 of 372 complaints reporting a plausible odometer (500 to 500,000 miles; unverified).
Known issues
The component families with the most complaint records against this vehicle. Counts, crash and fire figures belong to the whole family, not to any single named issue. Parts listed are related system parts, not a diagnosis.
Power train
149 complaint records1 fire report3 crash reports
"2002 MERCURY MOUNTAINEER TRANSMISSION FAILURE! COMMON PROBLEM AND SHOULD BE A FACTORY RECALL. THOUSANDS TO REPAIR!!!!! *TR..."- one owner's federal complaint about this system; it may not describe the issue named above
Parts
No specific part is named for this issue. Browse power train parts in the directory →
Body & structure
73 complaint records
"WITHOUT WARNING RIGHT SIDE LIFTGATE HINGE SNAPPED, CAUSING THE LIFTGATE TO HIT THE CONSUMER IN THE CHEST.*AK PE04045_PCO..."- one owner's federal complaint about this system; it may not describe the issue named above
Parts
No specific part is named for this issue. Browse body & structure parts in the directory →
Suspension
42 complaint records
"AT 43577 MILES I AM HAVING TO REPLACE MY REAR-END. THIS IS GOING TO COST APPROXIMATELY. 1500.00. ALSO ABS SENSOR HAS TO BE REPLACED. *LA..."- one owner's federal complaint about this system; it may not describe the issue named above
Parts
No specific part is named for this issue. Browse suspension parts in the directory →
Federal defect investigations
Formal investigations opened by the federal safety agency into this vehicle. An investigation is the step between a complaint pattern and a recall; not every one results in one.
| Investigation | Status | Component | Subject |
|---|---|---|---|
| EA09013 opened Aug 2009 | closed Feb 2013 | Steering | Vehicle Rollaway Allegations 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... |
| DP05005 opened Sep 2005 | closed Jan 2006 | Engine And Engine Cooling | SPARK PLUG EJECTION FROM CYLINDER HEAD 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... |
| PE05037 opened Jul 2005 | closed Nov 2005 | Vehicle Speed Control | STUCK ENGINE THROTTLE 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... |
| PE04045 opened Jun 2004 | closed Sep 2004 | Structure | REAR LIFTGATE GLASS ASSEMBLY - led to recall 04V442000 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... |
| EA02010 opened Jul 2002 | closed Feb 2003 | Air Bags | MIS-ASSEMBLED AIRBAG CLOCKSPRING IN JULY 2001, FORD ISSUED A SPECIAL SERVICE MESSAGE ANNOUNCING THAT SOME AIR BAGCLOCKSPRING DEVICES MAY PRODUCE NOISE WHEN THE STEERING WHEEL IS TURNED FULL LEFT OR RIGHT.FORD WAS AWARE THAT SOME CLOCKSPRINGS MAY HAVE BEEN IMPROPERLY INSTALLED.THE IMPROPER... |
Recall campaigns
Safety-recall remedies are normally provided at no charge. Under US federal law the mandatory free remedy applies when the vehicle was no more than 15 years old at the time the defect was determined; manufacturers often cover older vehicles voluntarily. Canadian rules differ. Confirm eligibility with the manufacturer using the VIN. Each campaign number links to the federal record.
| Campaign | Component | Summary | Remedy |
|---|---|---|---|
| 09V399000 | Vehicle Speed Control | FORD IS RECALLING MODEL YEARS 1995-2003 WINDSTAR, 2000-2003 EXCURSION DIESEL, 1993-1997 AND 1999-2003 F-250 SD THROUGH F-550 SD DIESEL, 1992-2003 E-150 THROUGH E-550, 1995-2002 EXPLORER, 1997 AND 2002 MERCURY... | Normally free |
| 01V171000 | Tires | VEHICLE DESCRIPTION: SPORT UTILITY VEHICLES. THE RIGHT SIDE TIRES MAY HAVE HORIZONTAL CUTS ON THE EDGE OF THE TREAD THAT COULD HAVE OCCURRED DURING VEHICLE ASSEMBLY. | Normally free |
Transport Canada recalls
Recalls issued under Canadian law for this model year, from Transport Canada's Vehicle Recalls Database. Matched by model name, so a Canadian-market variant may appear here that was sold under another name in the US. Units are Canadian vehicles affected.
| Recall | System | Units (CA) | Summary |
|---|---|---|---|
| 2009292 2009-10-14 | Other | 492,877 | On certain vehicles, the speed control deactivation switch may overheat, smoke, or burn, potentially resulting in an underhood fire. The condition may occur either when the vehicle is parked or when it is in operation. |
Service bulletins and warranty extensions
Manufacturer communications to dealers on file with the federal agency: repair instructions, service campaigns, and warranty extensions. A warranty extension means the manufacturer may pay for a repair the recall table does not cover.
| Bulletin | Type | Component | Summary |
|---|---|---|---|
| TSB 19-2026 Feb 2019 | Structure | 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. | |
| TSB-08-19-3 May 2009 | Power Train | 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 | |
| 07212 Oct 2007 | Engine And Engine Cooling | 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 | |
| 06216 Jan 2006 | Power Train | LIMITED SLIP AXLE CHATTER, SHUDDER, BINDING SENSATION, OR VIBRATION DURING LOW SPEED TURNING MANEUVERS. *TT | |
| 05213 Jan 2006 | Fuel System | 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 |
Show 55 more bulletins
| Bulletin | Type | Component | Summary |
|---|---|---|---|
| 05N04 Dec 2005 | Engine And Engine Cooling | EXTENDED COVERAGE PROGRAM 05N04 - EXTENDED COVERAGE FOR COMPOSITE INTAKE MANIFOLD. THIS PROGRAM IS BEING PROVIDED AS A SETTLEMENT TO A CLASS ACTION LAWSUIT. | |
| 041601 Nov 2005 | Engine And Engine Cooling | WDS COP KIT DIAGNOSTIC TIP - COIL ON PLUG (COP) IGNITION SYSTEMS - ENGINE MISFIRE OR ROUGH RUNNING. *TT | |
| 042115 Oct 2005 | Fuel System | FUEL GAUGE SLOW TO UPDATE AFTER REFUELING. *EH | |
| 051710 Oct 2005 | Suspension | NOISE FROM REAR WHEEL HUB BEARINGS. *TT | |
| 18719 Jul 2005 | Fuel System | MALFUNCTION INDICATOR LAMP COMING ON WITH DIAGNOSTIC TROUBLE CODES (DTCS) P0171, P0172, P0174 AND/OR P0175 (FUEL SYSTEM TOO RICH OR LEAN). *TT | |
| 04105 Jun 2005 | Power Train | AXLE SEAL LEAKS. LEAKS FROM REAR HALFSHAFT AXLE SEAL. SERVICE TIPS. *TT | |
| 0537 Jun 2005 | Power Train | DRIVELINE 1ST ORDER VIBRATION/BOOM/DRONE. *TT | |
| 042421 Jun 2005 | Seat Belts | SAFETY BELT RETRACTION SPEED. *TT | |
| 18572 Apr 2005 | Engine And Engine Cooling | NO START/HARD START N HOT SOAK RESTART. *TT | |
| 05618 Apr 2005 | Power Train | REAR AXLE NOISE REPAIR. *TT | |
| 05416 Mar 2005 | Seats | FRONT SEAT(S) SLIGHT MOVEMENT WHEN ACCELERATING AND/OR DECELERATING. *TT | |
| 04259 Jan 2005 | Visibility | REAR POWER WINDOW(S) INOPERATIVE. *TT | |
| 0485 Jan 2005 | Structure | LIFTGATE GLASS APPLIQUE DAMAGED/CRACKED. SERVICE PROCEDURE. *TT | |
| 18381 Jan 2005 | Electrical System | OPEN FUSE F2.20 (5 AMP) AND/OR F2.1 (30 AMP) WHICH MAY RESULT IN LOSS OF FUNCTION OF SEVERAL SYSTEMS INCLUDING POWER SEATS, ADJUSTABLE PEDALS AND POWER DOOR LOCKS. *TT | |
| 050618 Jan 2005 | Suspension | REAR AXLE NOISE REPAIR. *SC | |
| 051313 Jan 2005 | Engine And Engine Cooling | HARD START/NO START CONDITION DURING COLD AMBEINT TEMPERATURES AFTER SHORT HOT SOAK PERIOD-4.0L ENGINE. *SC | |
| 05136 Jan 2005 | Visibility | BACKGLASS DIFFICULT TO CLOSE AND AN INTERMITTENT DOOR AJAR LAMP. *TT | |
| 0471 Dec 2004 | Electrical System | WARNING INDICATORS-PARKING AID-REVERSE SENSING SYSTEM (RSS) AND FORWARD SENSING SYSTEM (FSS)-FALSE ACTIVATION OF WARNING TONE-SERVICE TIPS. *MJ UPDATE. *TT | |
| 04251 Dec 2004 | Structure | ALUMINUM CORROSION - SERVICE TIP. *TT | |
| 04189 Dec 2004 | Visibility | REAR WINDOW DEFROSTER GRID/INTEGRAL ANTENNA DIAGNOSIS AND REPAIR - TERMINAL TAB REPAIR. *TT | |
| 042107 Dec 2004 | Power Train | GENERAL (PCM) POWER TRAIN CONTROL MODULE PROGRAMMING PROCEDURES. *TT | |
| 03254 Dec 2004 | Power Train | 5R55W TRANSMISSION - NO 3RD GEAR OR SLIPPING 2-3 SHIFT - DIAGNOSTIC TROUBLE CODE P0733 AND P0745 - VEHICLES BUILT PRIOR TO 3/4/2002. *TT | |
| 042212 Nov 2004 | Power Train | GEAR SELECTOR LEVER - INCREASED EFFORT TO SHIFT FROM DRIVE TO PARK. *TT | |
| 04217 Nov 2004 | Power Train | GENERAL POWER TRAIN CONTROL MODULE (PCM) PROGRAMMING PROCEDURES. *TT | |
| 18215 Oct 2004 | Structure | BROKEN REAR CARGO STORAGE DOOR LIFT HANDLE. VARIOUS MODELS INCLUDING 2005 EXPLORER/MOUNTAINEER. *TT | |
| 18217 Oct 2004 | Fuel System | MULTIPLE VEHICLES - FUEL LEVEL INDICATION CONCERNS - SERVICE TIP. VARIOUS MODELS INCLUDING 2005 SUPER DUTY F-SERIES, EXCURSION, EXPEDITION, EXPLORER, MOUNTAINEER AND AVIATOR. *TT | |
| 18221 Oct 2004 | Power Train | REAR AXLE NOISE. OASIS. VARIOUS MODELS INCLUDING 2005 EXPLORER, MOUNTAINEER AND AVIATOR. *TT | |
| 18224 Oct 2004 | Fuel System | RUNS ROUGH OR MISFIRE - DIAGNOSTIC TROUBLE CODES P0300-P0308 OR P0316. *TT | |
| 03198 Sep 2004 | Power Train | CHATTER, SHUDDER, A BINDING SENSATION, OR VIBRATION DURING LOW SPEED TURNS ON VEHICLES EQUIPPED WITH THE 9.75 INCH OR 8.8 INCH LIMITED SLIP REAR AXLE. *TT | |
| 04174 Sep 2004 | Electrical System | MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - SYSTEM LEAN DIAGNOSTIC TROUBLE CODES (DTC'S) - SERVICE TIPS. VARIOUS MODELS INCLUDING 2004 F-SERIES. *TT | |
| 18121 Sep 2004 | Fuel System | FUEL GAUGE SLOW TO UPDATE. *TT | |
| 18123 Sep 2004 | Power Train | UPDATED REAR HALFSHAFT REMOVAL PROCEDURE. *TT | |
| 18171 Sep 2004 | Electrical System | NO CRANK/NO START CONDITION WHEN VEHICLE TEMPERATURE IS BELOW FREEZING (32F/0C). *TT | |
| 031404 Aug 2004 | Engine And Engine Cooling | ENGINE MISFIRE OR RUNNING - COIL ON PLUG (COP) IGNITION SYSTEMS - WDS COP KIT DIAGNOSTIC TIPS. TO INCLUDE VARIOUS 2005 MODELS. * AR THIS ARTICLE 04161 SUPERSEDES TSB 03-14-04. | |
| 041514 Aug 2004 | Visibility | REAR WINDOW DEFROSTER GRID/INTEGRAL ANTENNA DIAGNOSIS AND REPAIR - TERMINAL TAB REPAIR. *TT | |
| 031501 Jul 2004 | Visibility | INOPERATIVE ELECTRIC REAR WINDOW DEFROSTER (HEATED BACKLITE) GRID LINES, INTEGRAL ANTENNA CONCERNS. *TT | |
| 17905 Jul 2004 | Power Train | MULTIPLE VEHICLES USING FEHP REAR AXLE FLUID. FLUID USAGE CHANGE. *TT | |
| 04111 Jun 2004 | Electrical System | STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MALFUNCTION INDICATOR LAMP (MIL) ON AND DIAGNOSTIC TROUBLE CODES (DTCS) P0401, P0402, P1400 OR P1401. ADDITIONAL SYMPTOMS MAY INCLUDE RUNS ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY. *TT | |
| 02M01 Jun 2004 | Engine And Engine Cooling | CUSTOMER SATISFACTION PROGRAM 02M01 SUPPLEMENT #4. CERTAIN FORD 2000 THROUGH 2003 VEHICLES EQUIPPED WITH A TUBE-MOUNTED EGR PRESSURE SENSOR - ADDITIONAL EGR PRESSURE SENSOR WARRANTY COVERAGE. *TT SUPPLEMENT #3. *MJ SUPPLEMENT #6. *TT | |
| 04B15 May 2004 | Power Train | REAR AXLE DATE CODE INSPECTION AND SERVICE. VEHICLES MAY HAVE BEEN BUILT WITH AN IMPROPER MIX OF REAR AXLE LUBRICANT AND FRICTION MODIFIER ADDITIVE. IF SO, THE CUSTOMER MAY EXPERIENCE NOISE AND VIBRATION WHILE DRIVING. *TT *MJ | |
| 17717 Apr 2004 | Power Train | REAR AXLE CHATTER, SHUDDER, BINDING SENSATION, OR VIBRATION DURING LOW SPEED TURNS. *TT | |
| 17729 Apr 2004 | Equipment | MESSAGE CENTER DISPLAYS COMPUTING FUEL INSTEAD OF DISTANCE TO EMPTY. *TT | |
| 17736 Apr 2004 | Power Train | REAR AXLE NOISE. *TT | |
| 17640 Mar 2004 | Air Bags | POOR FIT BETWEEN DRIVER AIR BAG AND STEERING WHEEL. *TT | |
| 17641 Mar 2004 | Power Train | REAR 3.55 AXLE NOISE. CERTIFIED REAR AXLE OR IMPROVED GEAR SET AVAILABLE. *TT | |
| 17544 Feb 2004 | Engine And Engine Cooling | GENERATOR NOISE IN COLD AMBIENT TEMPERATURES. *MJ | |
| 17555 Feb 2004 | Power Train | CERTIFIED REAR AXLE AVAILABLE. *MJ | |
| 17560 Feb 2004 | Power Train | REAR AXLE NOISE. ALSO INCLUDES LINCOLN AVIATOR 2002. *MJ | |
| 03223 Jan 2004 | Electrical System | STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MALFUNCTION INDICATOR LAMP ON AND DIAGNOSTIC TROUBLE CODES (DTCS) P0401, P0402, P1400 OR P1401. ADDITIONAL SYMPTOMS MAY INCLUDE RUNS ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY. *TT | |
| 17494 Jan 2004 | Fuel System | DISTANCE TO EMPTY NOT DISPLAYED. *TT | |
| 04181 Jan 2004 | Wheels | CLEAR COAT PEEL OFF THE WHEEL OR CRACKS THAT LOOK LIKE SPIDER WEBS UNDER THE CLEAR COAT - 16 INCH WHEELS. *TT | |
| 03256 Dec 2003 | Engine And Engine Cooling | ENGINE-ROMEO BUILT 4.6L 2V-TICK NOISE FROM ENGINE-ENGINES BUILT BEFORE 9/17/2003. *MJ | |
| 17316 Nov 2003 | Fuel System | FUEL SIGNAL TO INSTRUMENT CLUSTER SERVICE TIP. *TT | |
| 17375 Nov 2003 | Electrical System | MALFUNCTION INDICATOR LAMP (MIL) ON AND HARD START/LONG CRANK. *TT | |
| 03203 Oct 2003 | Electrical System | MALFUNCTION INDICATOR LAMP ILLUMINATED WITH DIAGNOSTIC TROUBLE CODES (DTCS) P0442, P0455, P0456, P0457 OR P1442 OR A CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 FOR THE EVAPORATIVE EMISSION SYSTEM. *TT |
Showing 60 of 244 distinct bulletins on file for this vehicle.
Before you buy this vehicle
A test-drive checklist generated from this vehicle's own complaint and recall record.
- Drive it from a dead stop, twice, on a hill if you can.Shudder, hesitation, or a lurch under light throttle is how this vehicle's largest complaint cluster shows itself. Then ask for the transmission service history in writing; repeat repairs are a pattern, not a fluke.
- Walk the body slowly in daylight.Panel gaps, rust at the rockers and wheel arches, and cracked trim are this vehicle's structure complaints. Open and close the liftgate or trunk and look at the latch area.
- Find the roughest road nearby.Clunks over bumps, a droning hum that changes when the car leans, or a corner that sits low are this vehicle's suspension complaints. Wheel bearings and control arm bushings lead the parts list.
- Run the VIN against open recalls before you negotiate.This vehicle has 2 recall campaigns on file. An open recall needs VIN-specific confirmation. Many are quick, no-charge fixes and worth negotiating over; an unresolved do-not-drive advisory, or a remedy the manufacturer has not yet made available, should stop the purchase until it is resolved.
- Ask for the service history in writing, then read it against this page.The complaint families above are where owners of this vehicle report trouble. Repairs in exactly those systems are evidence the car had the problem; no such repairs could mean it never developed it, or that it was never fixed. The test-drive items above are how you tell those apart.
Parts search directory
The generic parts list for this vehicle has its own page: a search launcher for every system, filtered by fuel type and era but not by engine, trim, or brake type. It is not a diagnosis and not a fitment guarantee.
Open the parts directory for this Mercury Mountaineer →