Summary
The Mercury Cougar has 28 recalls spanning the 1968–2002 production run, with the most serious recent issue being a defective brake master cylinder on 2002 models where brake fluid loss can reduce line pressure and extend stopping distances enough to cause a crash.
The 2002 model year also has a fuel delivery module filter that can clog progressively, causing engine hesitation, power loss, or surging. Moving to 2000 models with the 2.5L V6, a misrouted battery cable can wear through its insulation where it contacts the power steering line, creating a short that can start a fire or leave the vehicle unable to start. On non-ABS 2000 models operated in regions where salt is used on roads, a rear brake pressure-reducing valve can corrode and malfunction, causing the rear wheels to lock during braking and making the vehicle difficult to control. The 1999 model year carries several issues: door latches with a humidity-sensitive coating can stick in the unlatched position, allowing a door to swing open while driving; an accelerator cable burr can cause the throttle to stick open and hold high engine rpm after the pedal is released; a heater blower resistor connector can arc and melt, raising the risk of fire; a misrouted battery cable can short against the power steering line; and the brake lamp switch terminals can overheat, causing the brake lights to fail or stay on constantly. On 1992 models, nylon fuel lines rubbing against the floor pan can wear through and leak fuel near ignition sources, and the headlamp switch can overheat and briefly cut out the headlights when the fog lamps are used at the same time.
Going further back, 1989 models have front seat belts that can fail to retract after extension due to a broken tension reliever cable, leaving occupants less protected in a crash. That same year, a full-lock low-speed turn can push the front brake caliper against the stabilizer bar, displacing fluid back to the reservoir and causing a noticeably soft pedal on the next brake application. The 1985 model has a brake master cylinder with improperly finished internal surfaces that can wear the piston seal prematurely, disabling one half of the split brake circuit and lengthening stopping distances. The 1983 model with the 3.8L engine has fuel tanks with weakly welded front seams that can develop fuel leaks and create a fire risk. The 1982 propane variant has fuel tank support straps that may not hold the tank securely in a collision. The 1981 model was shipped without catalytic converters or heat and grass shields, and the 1980 model can have its evaporative emission canister broken during rail transport. The 1979 model has rear seat track mounting welds that can pull loose under load or in a crash. The 1978 model has front seat belt retractors that may not lock during a sudden stop, leaving front occupants unrestrained. The 1977 model with the 351 Windsor engine and air conditioning has a five-blade cooling fan prone to resonant cracking, with blade fragments capable of separating at speed. The earliest recall, on the 1968 model with bucket seats, involves a driver's seat back pivot bracket that can fracture without warning, dropping the driver backward and causing loss of control.
