Summary
The Mercury Zephyr has 6 recalls covering the 1978-1980 production run, with the most serious affecting 1978 models where mismatched rear axles were installed between sedans and station wagons, causing early wheel lockup on sedans during braking and reduced stopping power on wagons.
The 1980 model year has a rear axle assembly that may contain brake components intended for a different vehicle, which can cause the brakes to fall short of required stopping performance. On 1979 models, windshields were installed without the required primer on the mounting surface, which can weaken the bond holding the glass in place during a crash. Turning back to 1978, vehicles with the 302 cubic inch engine were sometimes fitted with manual brakes instead of the specified power brakes, reducing braking force and potentially failing to meet required stopping standards. There is also a wiring harness routed against a brake pedal support brace on 1978 models that can chafe over time, ground one or more wires, and cause the vehicle to stall. Rounding out the 1978 recalls, front disc brake rotors on vehicles equipped with front disc brakes can contain cracks that fracture under braking, pulling the vehicle to one side and reducing steering control.
