Manifold/header/muffler/tail Pipe problems of the 1996 Mercury Villager

Eight problems related to manifold/header/muffler/tail pipe have been reported for the 1996 Mercury Villager. The most recently reported issues are listed below.

1 Manifold/header/muffler/tail Pipe problem

Failure Date: 12/04/2003

The stud bolts are (is) broken on exhaust manifold. Exhaust fumes are leaking and cold air may enter head. Repair is extremely high because of position of bolts. We are afraid to drive it but cannot stop using it. Also we cannot afford to fix it.

2 Manifold/header/muffler/tail Pipe problem

Failure Date: 08/01/2003

Exhaust fumes entered the passenger cabin. The problem was with the front and rear exhaust manifold.

3 Manifold/header/muffler/tail Pipe problem

Failure Date: 07/01/2003

My 1996 Mercury Villager has been diagosed as having broken exhaust manifold bolts. After searching the web, it's become apparent that this is an extremely common problem with certain model years of the Mercury Villager, including mine. The design of this part of the car is definitely flawed because of the commonality of this problem.

4 Manifold/header/muffler/tail Pipe problem

Failure Date: 05/15/2003

Exhaust manifold bolts sheared off, allowing exhaust fumes to seep into interior of van. Have to drive with windows cracked open to avoid getting sick. After internet search found there are thousands of others with this same problem, but Ford refuses to do anything or help out with the costs which will be several 1000 $$.

5 Manifold/header/muffler/tail Pipe problem

Failure Date: 08/26/2002

Intake manifold bolt sheared off while traveling on highway. Exhaust fumes were leaking from pipe area. Dealership is aware of problem.

6 Manifold/header/muffler/tail Pipe problem

Failure Date: 09/01/2001

Exhaust gases escaping into the passenger compartment because of an exhaust manifold bolt failure.

7 Manifold/header/muffler/tail Pipe problem

Failure Date: 03/13/2001

A day after taking vehicle for manufacturer's recall awf40c-f 00 s 59 repairs filler hose had to be changed because it could cause a fire. When consumer was driving about 40 mph engine started jumping. Then, caught on fire just like it said in recall. The vehicle had exhaust leak at the manifold. The consumer says he does not know the cause of the fire.

8 Manifold/header/muffler/tail Pipe problem

Failure Date: 06/01/2000

Exhaust manifold bolts shearing off, requiring drilling out, replacement. Internet search reveals that quest, pathfinder, and Villager all have similar affliction. Manufacturer has agreed to pay for 80% of repair cost to fix it, even though vehicle is out of warranty. $1000. 00 to $3,000 to fix. Exhaust fumes are seeping into cab, requiring opening of windows. By offering to pay are they not admitting there is a problem? recall issue?.

Manifold/header/muffler/tail Pipe problems	8
Gasoline Engine problems	6
Engine Noise problems	5
Car Stall problems	4
Engine problems	3
Engine Clicking And Tapping Noises problems	3
Engine Stall problems	2
Gas Recirculation Valve (egr Valve) problems	2
Engine Exhaust System problems	2
Timing Tensioner problems	2
Emission Control problems	2
Engine Belts And Pulleys problems	1