1997 Mercury Villager Problems

What owners report

Owners of the 1997 Mercury Villager most frequently report fuel system issues involving leaking or cracked vent hoses and filler pipe connectors, along with power door locks that engage on their own without any input. Exhaust manifold bolt failures and airbag deployment concerns also appear regularly across complaints. Several complaints involve difficulty getting recall repairs completed due to parts shortages at dealers.

1. 1
   Fuel system

   Fuel leak and gasoline odor (vent hose / filler hose)

   • 22 complaints (18%)
   • median 125,304 mi at 9.7 yrs old (6 state mileage, few)
   • filed 1998–2011

   Owners report smelling strong gasoline odors inside and outside the vehicle, and in some cases finding fuel puddles under the van after filling the tank. Complaints frequently reference cracked or failed vent hoses and filler pipe connector hoses. According to complaints, dealers sometimes replaced the vent hose for a service charge rather than under recall coverage, and some owners report the repair failing a second time in the same location. Reported across a wide mileage range; complaints with known mileage include reports at around 68,000, 100,000, 106,000, 144,500, and 155,000 miles, with some occurring shortly after refueling.

   Recall 00V419002Recall 96V203000

   What to check: Ask whether recalls 96V203000 and 00V419002 were completed, and whether the vent hose or filler pipe hoses have been replaced more than once. Check under the vehicle and around the fuel filler area for any odor or staining after a full tank.

   2 excerpts from owner complaints in NHTSA records

   “Filler pipe vent hose was recalled in march 2001 recall#00s59 and replaced. The same part failed in the exact same manner and was replaced november 2003. Ford says that the filler pipe vent hose is out of warranty and will not pay any replacement costs. Did the march 2001 recall adequately address this problem?”

   NHTSA complaint #10071169, filed 2004-01, 145,000 miles

   “After the recall was done on a fuel hose the vehicle has on an off smelle of very strong gas fumes inside the passenger compartment and outside the van as well, took the vehicle back to the dealer and the fuming problem seemed to be coming from a gap in the body seam area of the vehicle in which they sealed, possible of manufacturing defect.”

   NHTSA complaint #563719, filed 2001-10
2. 2
   Latches, locks and linkages

   Power door locks self-activating or malfunctioning

   • 27 complaints (22%)
   • median 45,000 mi at 4.5 yrs old (1 states mileage, few)
   • filed 1998–2004

   Owners describe all doors locking by themselves with no button press, whether the vehicle is running, parked, or even with the engine off. Complaints note the problem occurs both while driving and while stationary, and several owners report children becoming locked inside as a result. According to complaints, dealers repeatedly attempted repairs without success, and some were told no recall or corrective action existed. Complaints span a broad range without consistent mileage data; one complaint notes the issue began around 20,000 miles, and others describe it persisting for years of ownership, with some noting it seems worse in hot weather.

   What to check: Test all door lock switches and the remote before purchasing, and ask whether the door lock actuators have ever been replaced. Check whether any doors fail to unlock or lock on command.

   2 excerpts from owner complaints in NHTSA records

   “All of the doors lock by themselves. It has happened many times. We can be out of the car or in it. The keys can be out of the ignition. It usually happens when we are parked but it has also happened when we were driving. There have been numerour times whenwe have tried to unlock the car with the remote and it quickly locks itself back up; this may repeat itself for or five times before we can get into the car.”

   NHTSA complaint #752525, filed 2001-09

   “Our doors lock by themselves intermittently. Mostly happens when vehicle is shut off and doors are unlocked, as the passenger side door is opened the doors (all) lock again. It has happened a few times when the doors are shut, the vehicle will lock by itself. It once did it with a child inside and we had to get the other set of keys to unlock it. This could have been more of a problem if the other keys were not in close poroximity.”

   NHTSA complaint #752303, filed 2001-09
3. 3
   Air bags

   Airbag unexpected deployment or warning light

   • 10 complaints (8%)
   • median 134,912 mi at 10.3 yrs old (1 states mileage, few)
   • 2 mention a crash, fire or injury
   • filed 1998–2007

   Owners report both front airbags deploying unexpectedly at very low speeds or without a significant impact, including one account of deployment while crossing a slight bump at low speed. Other complaints describe the airbag warning light illuminating or the airbag cover panel lifting away from the dashboard. According to complaints, dealers repaired airbags under warranty in some cases but attributed the deployment to general wear. Complaints with known mileage include a report at approximately 134,912 miles; other complaints do not include mileage data.

   What to check: Confirm whether the airbags have ever deployed and been replaced, and ask a mechanic to check that the airbag system warning light is not illuminated at startup.

   2 excerpts from owner complaints in NHTSA records

   “Driving at aprroximately 70 MPH vehicle hydroplaned, went into a spin and hit a bridge rail with right front bumper. Dual airbags did not deploy which could have caused injuries and total loss of vehicle.”

   NHTSA complaint #838664, filed 1999-06

   “Driver was at a stop and lifted foot off the brake and lightly rear ended another vehicle at about 1-2mph, and both driver's side and passenger's side airbags deployed. Dealer has seen vehicle.”

   NHTSA complaint #869034, filed 2000-08
4. 4
   Engine cooling

   Exhaust manifold bolt failure and exhaust leak

   • 10 complaints (8%)
   • median 81,000 mi at 7.7 yrs old (1 states mileage, few)
   • filed 1998–2004

   Owners report exhaust manifold studs or bolts breaking off in the engine, resulting in audible exhaust leaks and the check engine light coming on. Complaints describe fumes entering the passenger compartment and note that repair costs range from several hundred to over a thousand dollars. According to complaints, some dealers acknowledged a hidden extended warranty on the part while others did not. Complaints with known mileage reference the problem at approximately 81,000 miles, and descriptions suggest it tends to appear as the vehicle ages.

   What to check: Have a mechanic inspect the exhaust manifold studs for signs of breakage or exhaust leaks before buying, and ask whether this repair has already been performed.

   2 excerpts from owner complaints in NHTSA records

   “I am one of tons of people with the notorious exhaust manifold studs breaking issue! Which causes the check engine like to come on, and dangerous fumes to enter the vehicle. With 4 children, this is not a good thing...and the price is more then a family of 4 children can afford at $1500-3000 depending on the damage and now I cannot have my vehicle safely inspected due to this issue. Please have them issue a recall on this and protect our families.”

   NHTSA complaint #10078559, filed 2004-06, 81,000 miles

   “Consumer was traveling about 65mph on highway, and without prior warning, vehicle shut off. Lost power brakes and steering. Dealership was aware of the problem. She paid to have vehicle put on a machine, but problem couldn't double itself.”

   NHTSA complaint #894768, filed 2001-08

Buying note. Prospective buyers should verify that the two fuel system recalls (96V203000 and 00V419002) have been completed, since complaints indicate parts shortages delayed repairs for many owners and some hoses failed a second time. A pre-purchase inspection focused on the exhaust manifold studs, door lock actuators, and fuel system connections is advisable given the patterns in these complaints.

Summary written with AI from a sample of 60 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.