| Issue ID | 781708 |
| Internal NHTSA # | 10323700 |
| Manufacurer | FORD MOTOR COMPANY |
| Brand | MERCURY |
| Model | MONTEREY |
| Model Year | 2004 |
| File date | 26/03/10 |
| Component | POWER TRAIN:AUTOMATIC TRANSMISSION |
| Product type code | VEHICLE |
| Description of the problem | Vehicle suddenly and unexpectedly lost power while wife was driving on level terrain with two passengers at constant speed of approx. 65 mph in right lane of an interstate. Engine rpm increased but vehicle speed decreased. Power loss was complete. Fortunately a rest area was within coasting distance and vehicle was able to come to a safe stop there. Engine would crank and run but vehicle would not move in any gear, forward or reverse. Vehicle was towed to a ford dealer, who diagnosed transmission failure. Vehicle was repaired at a cost of approx. $3,300 by replacing transmission and torque converter with ford remanufactured parts. I personally reviewed the failed transmission and torque converter when i picked up the repaired vehicle. Due to the substantial core charge (approx. $600) i allowed the dealer to keep the parts for return to ford. While reviewing the parts, i was able to identify and photograph what appeared to be the root cause of the failure. All teeth of the pump drive spline (a female spline inside the torque converter) were sheared off so that the spline bore was completely smooth. (i also observed and photographed an undamaged converter for comparison.) there was no damage to the mating male pump drive spline on the transmission. The nature of this failure clearly points to a design or manufacturing defect. The failed spline teeth must have been soft or they would have damaged the mating teeth on the male spline. The failed spline component appeared to be a stamped 1/8" thick steel washer which was welded to the inside of the torque converter case. Failure of this component suggests that its design thickness and strength were grossly inadequate to support the pump drive load for the service life of the vehicle. It is extremely dismaying to have the failure of a less than $2 component result in a potentially life-threatening situation and a very expensive repair bill. Of particular concern is that there was absolutely no warning of impending failure! |
| Vehicle Mileage at Failure | 75136 |
| Number of Occurences | 1 |
| Source of the issue | NHTSA WEB SITE |
| City and State | BARTLETT, TN |
| VIN pattern | 2MRDA20274BXXXXXX |
| Was vehicle invloved in a crash? | N |
| Was vehicle involved in a fire? | N |
| Was incedent reported to police? | N |
| Was medical attention required? | |
| Was part original equipment? | |
| No. of injured persons | |
| No. of fatalities | |
| Date of purchase | 07/08/26 |
| Was original owner? | N |
| Anti-lock brakes | N |
| Cruise control | N |
| Number of cylinders | |
| Drive train type | |
| Transmission type | |
| Vehicle speed | 65 |
| DoT tire identifier | |
| Tire size | |
| Location of tire code | |
| Type of tire failure code | |
| Was defective tire repaired? | |
| Date of manufacture | |
| Type of child seat code | |
| Type of restraint | |
| Dealer's name | |
| Dealer's telephone number | |
| Dealer's city | |
| Dealer's state code | |
| Dealer's ZIP code |