Two problems related to engine exhaust system have been reported for the 1996 Mercury Villager. The most recently reported issues are listed below.
I noticed there was an exhaust smell seeping into the van, I did some research on the internet and found that it was a common problem with quest's and Villager's snapped exhaust manifold studs. I checked under the hood and sure enough there were 2 studs broken and missing. I called several dealers and got quotes and found a Nissan dealer to do it for $800 they seem to have more experince doing it since it also is a problem with pathfinders and maximas. I called Ford and they flat out refused to help out at all!.
Heat shield around exhaust system loose.