1991 Mercury Cougar Problems

What owners report

Owners of this model year most often report engine overheating with failed head gaskets, and headlights that flicker, dim or go out while driving. Other complaints describe smoke or flames from the steering column and unexpected acceleration, including cases where cruise control would not disengage. Mileage in the reports ranges widely, from around 60,000 miles to over 140,000, so the problems described are not limited to low-mileage cars.

1. 1
   Engine cooling

   Blown head gasket and overheating

   • 10 complaints (14%)
   • typically at 9.3 yrs old
   • filed 1997–2006

   Owners describe the engine overheating, sometimes with white smoke from the tailpipe and a sluggish feel, and being told the head gaskets had failed. Several complaints mention repeat repairs, including a gasket that failed again after a resurfacing job. One owner reports being told the heads and block were not cracked, unlike other cases their mechanic had seen. Owners who give mileage report failures between roughly 60,000 and 98,000 miles, and many complaints do not state mileage at all.

   What to check: Ask about cooling-system and head gasket history, watch for white exhaust smoke or a sweet smell, and check for coolant loss or a milky residue under the oil filler cap.

   2 excerpts from owner complaints in NHTSA records

   “Headlights go off while driving, brakes continue to make noise, key switch prob. Recall repair, heater blows cold, car died after excel. Restarted and drove 50 ft. Died again and know in shop & been told gaskets or busted head. I love this car and have taken extra care, engine and car keep spotless, car is never left outside. All took place within 1 mo. Is it all tied together with one thing?”

   NHTSA complaint #738145, filed 2000-12

   “The head gasket went bad even after routine regular maintenance and only 80,000 miles on the vehicle. According to a local dealership and several mechanics this is extremely common. I was fortunate because the heads and block were not cracked unlike the majority of the ones that are serviced. It seems that if the 3.8 liter has this problem then maybe there is a design flaw or quality problem with the gasket. …”

   NHTSA complaint #722078, filed 2000-04
2. 2
   Exterior lighting

   Headlights flicker, dim or go out

   • 9 complaints (12%)
   • median 102,500 mi at 17.5 yrs old (2 state mileage, few)
   • filed 1996–2009

   Complaints describe headlights flickering, dimming or shutting off while driving and then coming back on after a pause. Several owners link the behavior to heat and to the headlight switch, and more than one noticed a burning smell from the vents when it happened. In some cases the dealer replaced bulbs or other parts without the problem going away. Reported from about 64,000 miles to over 140,000 miles, often after the car has been running for a while.

   What to check: At night, watch for flicker, dimming or a burning smell from the vents with the lights on, and ask whether the headlight switch or the circuit breaker has been replaced.

   2 excerpts from owner complaints in NHTSA records

   “Headlights go out for various intervals and is preceded by flickering and/or blinking which causes loss of visibility which increases my risk of a crash. Also note a burning smell from vents when this happens. My vehicle is a 1991 Cougar and I went online to see if there was a recall for this problem. Noted recall for same problem on 1992 and 1993 models not for 1991. Called ford motor company and asked if there was a recall for my model since it has the same issue as 1992 and 1993 cougars. …”

   NHTSA complaint #10255020, filed 2009-01, 64,000 miles

   “Driving at any various speed headlights will turn off and on, causing the consumer to drive sometimes without headlight unexpectedly,which may result in an accident.dealer has replaced headlights 4 times, but defect is still occurring.”

   NHTSA complaint #820061, filed 1997-12
3. 3
   Electrical system

   Smoke or fire from the steering column

   • 9 complaints (12%)
   • median 102,500 mi at 17.5 yrs old (2 state mileage, few)
   • 7 mention a crash, fire or injury
   • filed 1995–2009

   Several complaints describe smoke or flames coming from the steering column, in some cases while the car was parked with the engine off. Owners point to the ignition switch and the wiring in the column as the source, and one report ties flickering lights to a short in a circuit breaker. The accounts describe the car being stopped and shut off rather than driven further. Mileage is often unstated; the complaint that gives it describes the problem at high mileage, around 141,000 miles.

   Recall 96V071000

   What to check: Ask whether the ignition switch has been replaced under the recall, and check for a burnt smell or discolored plastic around the steering column and under the dash.

   2 excerpts from owner complaints in NHTSA records

   “Drove vehicle about 200 yds, saw smoke coming from steering column, stopped & checked under hood, few minutes later flames were coming from steering column.”

   NHTSA complaint #986009, filed 1996-06

   “While parked in front of home, owner heard explosion sound; came out to check; vehicle was engulfed with flames inside and outside, underdash/underhood.”

   NHTSA complaint #983474, filed 1996-04
4. 4
   Vehicle speed control

   Unexpected acceleration and cruise control surge

   • 8 complaints (11%)
   • median 95,000 mi at 14.9 yrs old (1 states mileage, few)
   • 1 mention a crash, fire or injury
   • filed 1995–2005

   Owners describe the throttle opening on its own at highway speed, the pedal sticking down, and the car speeding up when cruise control is disengaged or after the selector is moved. In several accounts the only way to stop it was to switch the engine off. One owner says a dealer replaced a broken part under the hood years earlier and that the same behavior later returned. Mileage is mostly unstated in these complaints; one owner reports a recurrence around 95,000 miles.

   What to check: Test the throttle and cruise control on a quiet road, confirm the pedal returns freely by hand, and ask whether the throttle linkage or cruise servo has been serviced.

   2 excerpts from owner complaints in NHTSA records

   “Dt: the contact stated car was revving when starting it up. When putting it in drive in went down somewhat. It felt like it was going to take off by itself. This happened on 8-31-05. Back in 1998 the contact was having the same problem. She took it to a dealer, and they replaced a chip that had broken under the hood. She felt this was same problem that she experienced in 1998. The contact was planning to take vehicle to a dealer close to her as soon as possible. She was not going to drive the car because she was afraid. …”

   NHTSA complaint #10135063, filed 2005-09, 95,000 miles

   “While driving at 30mph the vehicle had an outburst of sudden acceleration. Consumer tried and stopped vehicle, it was placed in reverse and also park, but the vehicle kept on going. To stop vehicle consumer had to shut the engine off, and coasted the vehicle to a stop. Dealer was contacted.”

   NHTSA complaint #831660, filed 1998-12

Buying note. These cars are old enough that condition and maintenance history matter more than the model year, but this year's reports center on cooling-system work and headlights, so budget for a cooling-system inspection and check the lighting and column wiring before buying. Ask for records of any head gasket repair and confirm what was actually replaced.

Summary written with AI from a sample of 36 NHTSA complaints for this model year (picked at random, with complaints that state a mileage and recent ones taken first), then checked automatically against the source records. Where a problem shows a complaint count, every complaint for this model year was matched with fixed keyword rules (written with AI and tested against the sample), and the mileage, age and repair figures are calculated from those complaints; owners' figures are as stated, not verified. Other counts refer to the sample. The excerpts come from NHTSA's public complaint records and are unverified; capitalisation is normalised, NHTSA staff notes are removed, and shortened text ends with “…”. Something wrong? Request a correction.