Car Problem Reports

Mercury Villager Exhaust Manifold Can Warp and Cause the Studs to Break Off

Mercury Villager Problem
17 Reports
Me Too

Model Years Affected: 1993, 1994, 1995, 1996, 1997, 1998, 2000

Average Mileage: 177,657 mi (100,000 mi - 234,000 mi)


The exhaust manifold often warps and cracks, breaking off the studs between the cylinder head and the exhaust manifold. A ticking type noise may be noted most noticeable when the engine is cold.

  • , , 100,000 mi

    the rear manifold stud broke off causing exhaust leat

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  • , , 135,435 mi

    same prom, replace all rusted bolts and seals, that in turn restored lost power and gave me better fuel consumption.

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  • , , 234,000 mi

    studs broke on back mainfold

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  • , , 174,000 mi

    Same issue here, I do not see broken bolts, just hear ticking getting worse every time I start it. Worst w/ cold mornings.

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  • , , 154,000 mi

    we just got the water pump, two motor mounts, muffler, thermostat, rear exhaust gasket, new radiator and it STILL has a exhaust smell coming through the vents!!!!! what the hell did we miss? this car should be gone I think, but my husband thinks its still a good car. I can't drive it though because our son shouldn't ride in it.

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  • , , 167,000 mi

    I bought this Villager used 3 years ago, with about 130,000 miles on it. There was always a rattle when cold; I still think that may be the lifters, but at about 160,000 miles I developed a distinct exhaust leak. When I checked the exhaust manifold (rear side)I saw that four of the six studs had rusted & broken off. I dunno how long it was like that, but I'm sure they didn't all go at the same time; I'm amazed it held up this long. Now I have to decide whether it's worth it to repair the head, or just scrap it for $300.
    BTW; all four original tires blew out on me, one-at-a-time over the first year. They were new when I bought the car, but had NO manufacturer info on them anywhere. I advise checking tires carefully if buying from a budget used-car dealer. (Especially "Woodbridge Auto Auction" in VA.)

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  •  Rookie

    Engine ticks when cold. It seems to seal itself after the engine gets warm, but there is a noticeable loss of power, especially on hills. Have not tried to fix et. Dealer said it could be done by rebuilding the heads for $1500.

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