The 2006 Lincoln Zephyr has 6 recalls, the most serious being a Takata airbag defect affecting both the driver and front passenger inflators, where the inflator can rupture and send metal fragments into the cabin, causing serious injury or death.
Both the driver and passenger front airbag inflators are affected by this defect, which develops over time in vehicles exposed to high heat and humidity. Prior repair attempts did not fully resolve the issue, and multiple recall campaigns have addressed it in phases. The passenger-side inflator recalls specifically apply to vehicles originally sold or registered in high-humidity states and territories including Florida, Hawaii, Texas, and several others.
On the brake side, the anti-lock brake system's hydraulic control unit contains valves that can react with certain brake fluids and fail to close fully. When this happens, the brake pedal travels further than normal before the brakes engage, requiring more distance to stop the vehicle.
At a glance
What can fail
The driver's side air bag inflator may explode. This can happen when the propellant degrades after prolonged exposure to high heat, humidity, and temperature changes.
What the fix does
Dealers will replace the driver-side airbag inflator or module with a new one at no cost to you.
Summarized — see the official notice for exact wording, dates, and contacts.
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At a glance
What can fail
The driver-front airbag propellant may degrade over time from heat and humidity exposure. A degraded propellant could cause the airbag to deploy with excessive force or the inflator to rupture, sending fragments toward occupants.
What the fix does
Ford will replace the driver-front airbag inflator with a new one.
Summarized — see the official notice for exact wording, dates, and contacts.
At a glance
What can fail
The anti-lock brake system hydraulic control unit may malfunction, requiring more pedal pressure to stop the vehicle.
What the fix does
Dealers will flush the brake system with DOT 4 fluid, replace the hydraulic control unit if needed, and install a DOT 4 reservoir cap.
Summarized — see the official notice for exact wording, dates, and contacts.
At a glance
What can fail
Brake fluid additives can react with valves in the ABS hydraulic control unit, preventing them from closing properly and affecting braking performance.
What the fix does
Dealer will flush brake system with DOT 4 fluid, install new reservoir cap, test the control unit, and replace it if a stuck valve is found.
Summarized — see the official notice for exact wording, dates, and contacts.
At a glance
What can fail
The passenger front air bag inflator may rupture during a crash due to propellant breakdown from long-term exposure to humidity and temperature changes.
What the fix does
Dealers will replace the passenger front air bag inflator at no cost. Ford will mail recall notices and notify owners when parts are available.
Summarized — see the official notice for exact wording, dates, and contacts.
At a glance
What can fail
The passenger front air bag inflator may rupture during a crash due to propellant breakdown from long-term exposure to humidity and temperature changes.
What the fix does
Dealers will replace the passenger front air bag inflator at no cost once parts become available.
Summarized — see the official notice for exact wording, dates, and contacts.
