Manifold/header/muffler/tail Pipe problems of the 1996 Ford Crown Victoria - part 1

The contact owns a 1996 Ford Crown Victoria. The contact stated that the air intake manifold on the vehicle was manufactured out of plastic, which caused anti-freeze to leak onto the engine. The anti-freeze leak was noticed due to the burning chemical odor and smoke coming from under the hood. The dealer stated that the repairs would cost over $1,000 at the contact's expense. He was denied repairs under the class action lawsuit. When the heater was activated, the odor from the anti-freeze was overbearing in the passenger compartment of the vehicle. The failure and current mileages were 82,000. Updated 4/16/09 updated 04/20/09.

Dear sir or madam: I am aware of the Ford campaign 05n04 regarding the composite intake manifold replacement program. My 1996 crown vic fell to this defect to on 11/20/06 which resulted in a needed replacement using the prescribed Ford repair kit. My local Ford dealer said the repair program had expired with no reimbursement possible. After soliciting Fords comments directly (reply can be forwarded) I interpret their response that part failure, while the same as others, did not happen soon enough and therefore ineligible. In your opinion is there any recourse to appeal their denial for claim? are you still receiving letters/emails that this is an ongoing problem? might there be another judgment against them to cover others with this same failure? your help is appreciated. Thank you. Updated 02/15/07.

My wife while traveling to visit her son in a distant city, she pulled into a shopping center to call him, he lived nearby. He came to the shopping center in an effort to lead her to his residence. When leaving she noticed smoke and thought the vehicle caught fire. Further investigation proved it was an ant-ifreeze leak. The failure was the intake manifold produced of an inferior material (nylon) a crack developed at 100614 miles causing the antifreeze to leak out and overheat the engine and cause more damage. Within several day the auto went to the repair shop and the intake manifold was replaced a substantial cost. There was no recall present with this event however Ford motor company had a class action suit with this event as its center piece. Unfortunately the failure on my Ford occurred after the class action suit expired. The suit was limited by a time frame. My thought is all nylon manifold will fail far short of the expectations of the life of the engine.

I have one of the plastic intake manifold on a 1996 Ford crown vic that cracked. I contacted a dealer in tulsa and they said the recall was out of date and would not do the work. If they just recalled the part in 2004 or 2005 why would it not be covered now.

On a 1996 Ford Crown Victoria the intake manifold failed due to a severe crack on the underside,loosing coolant and causing over heating of engine and leaving us stranded. Car was repaired at a shop we have used for years at the cost of approx $700. 00.

I filed a statement with Ford motor company on January 26, 2006 with the original repair receipt and the defective manifold. I have not received any reply as of this date, I checked with the company on February 16 and was told it was being reviewed. What do they have to review? I have the receipt from July 2002, the original defective manifold, and the repair department manager filled out the papers and filed them. I filed the form at coconut point Ford , 22360 s. Tamiami trail, esteo, FL. And they said they had to send the form to sam galloway Ford inc, 1800 boy scout dr. , ft. Myers, FL. Since they are the ones to write the checks. I followed the directions to the letter for the claim and am not getting a response. I think they are waiting until March 16 is past then they will say I am too late to file. Please see what you can do for me.

1996 Ford cp intake manifold cracked at the seaam. . . . Manufacturer's recall, no notification.

I have a 1996 Ford Crown Victoria with a 4. 6l engine. I bought it March 16th 2005. On March 17th 2005 I drove it for the first time to work. I accelerated to 70 mph on the us-131. The intake gave out and smoked out the entire highway. It cracked on the front coolant runner of the intake manifold. I was alte to work and had to have the car towed. I am going to be charged about $600 for the replacement intake installled. The mechanic told me that the intakes were recalled, but only on commercial vehicles not private owned. Why is this? is the private citizen not important enough? I am living from paycheck to paycheck now, I can't afford to have this kind of work done. My income is limited. I can only hope I can scrape up the money, so I can get to work now. Not happy. I will keep the old part.

I had to replace the intake manifold on my 1996 Crown Victoria earlier this year. I received a letter about a lawsuit that the cost of the manifold would be reimbursed by Ford if the final settlement was approved. I have read the information provided and although Ford knowingly put a faulty part in my car, I will not receive a reimbursement simply because my repair is beyond the 7 years mentioned in the lawsuit. I want to know what can be done. Had I known that this part was inappropriate for the job that it was intended to do, I would not have bought the car. Even I know better than to put a plastic/vinyl part where the heat is so intense!!!!! Ford needs to be forced by the government to reimburse all of us ,. . . . . . . Period. I don't make a lot of money and had to use a house payment to pay for this and I still haven't caught up! Ford screwed me one time before back in the 80's and I screwed up by buying another Ford.

The contact owns a 1996 Ford Crown Victoria. While driving 10-15 mph, the thermostat stuck and became hot. The vehicle overheated and the intake manifold failed. The contact received a safety recall notice for the vehicle speed control. The vehicle has not been taken to the dealer because it cannot be driven. The purchase date and recall number were unknown. The current and failure mileages were 111,000.

While driving and without warning coolant leaked from intake manifold.

Intake manifold cracked. Contacted Ford customer service. Advised no recall at this time. Advised to retain receipt if recall issued, Ford would refund expense. Was advised that if I did not have repair made at Ford dealership there was no other way for their engineers to document and investigate the problem. Also aware the escambia county, FL sheriff's dept. Has to replace this same part on a regular basis. After reviewing the numerous complaints I find that a recall has been issued for police and taxi vehicles but not passenger vehicles. The cost of this part with a discount was $501. The replacement manifold has a metal water passage to prevent further cracks. Ford must be held accountable for this and forced to repair, replace or refund this defective major engine part.

I own a 1996 Ford Crown Victoria p71 interceptor. I have a serious problem with my intake manifold on the engine. The recalled part was not replaced by the department that previously owned the vehicle, and now it has failed 6 months after the expiration leaving me an unsafe vehicle, and risk of permanent engine damage or failure. Ford is not willing to assist in any way with this repair other than a standard near $800. 00 repair.

While driving at 30 mph driver noticed smoke coming from inside of the vents. Driver pulled over and lifted the hood up. The driver had the vehicle towed to the dealer for analysis. Mechanic noticed that the intake manifold cracked inside, causing a leak.

The contact owns a 1996 Crown Victoria. The contact stated that while driving approximately 55 mph, the vehicle stalled without warning. The vehicle was towed to an independent mechanic, who diagnosed that there was a small fractured in the manifold. The vehicle was not repaired. The contact stated that the manifold failure was recurring. The manufacture was made aware of the problem. The approximate failure mileage was 150,000. Updated 3/21/cn.

The contact owns a 1996 Crown Victoria. The contact stated that while driving approximately 55 mph, the vehicle stalled without warning. The vehicle was maneuvered to the side of the road. The contact stated that the manifold had failed for the second time in ten years. The vehicle was towed to an independent mechanic. The independent mechanic diagnosed that there was a small fracture in the manifold. The vehicle was not repaired. The manufactured was made aware of the problem. The approximate failure mileage was 150,000.

Plastic intake manifold cracked, fire hazard; major engine parts made of plastic, not made to with stand high heat temps. Replaced intake manifold, only available replacement is plastic as well, which will crack again!!!!.

The intake manifold cracked.

Consumer states intake manifold gasket is cracked, causing coolant to go inside the engine. Dealer notified.

The intake manifold failed.

While at work performing an alternator test on a 96 Crown Victoria with the 4. 6 engine I was running the engine at 2000 rpm. There was a loud pop and then the engine compartment was filled with steam and hot coolant. I was almost scalded, as I was leaning over the engine to access the throttle linkage. The intake had cracked on the coolant runner behind the alternator about 2" wide. Our shop had to replace the customer's intake manifold and could not charge the customer for the parts or labor because the customer blamed us for the damage. I believe that the customer should have been informed of this situation by Ford motor company and the recall should cover more than just the "fleet use" vehicles. This is clearly a product durability/defect issue.

Consumer states that intake manifold cracked, causing the fluid to leak onto the engine. Consumer has contacted the dealership.

There were problems with the engine. Manufacturer was contacted and stated the vehicle was not included on the recall even though the vehicle experienced the same problem with the manifold intake. Smoke come from under the hood. There was no water(was all over the engine and the insulation), and no oil. Plastic was used for the intake manifold which Ford changed to metal. The consumer's new engine had come with the new change. Ford instructed the consumer to keep receipts because the were going to issue a recall.

The engine manifold cracked.

The intake manifold cracked allowing coolant to leak which could get onto wiring and cause a fire, or engine over heating which could cause a fire. Ford has a recall on police cars and taxi's but not regular crown victoria's.

First I would like to say that what I hear about the grand marquis having problem with the fuel tank is rather disturbing to me I am aware now that these cars are capable of catching on fire if hit from behind. I carry three small children to school every morning in "this car" I have contacted the Ford corp. About this problem and they seem to not be bothered about this fact. Now to my other problems. I have just replaced my intake manifold because the one that came with the car cracked while I was driving it. My mechanic stated that he found out that it was a very common problem with the 1996 Mercury grand marquis. The Ford corp. Has redesigned the intake manifold for this model and raised the price from about 250. 00 to almost 500. 00. In July of 2002 there was a part that went out on my a/c unit that I had to replace (I have to contact my mechanic to see what part it was that was replaced) in July 2002 I had to have my roters turned, in January 2003, I had to have them turned agian and have my right back roter repaced because it was no longer good. (all this was done on January 10 2003 now it is Jan. 20, 2003 and my right front roter is grinding again (I also had new brakes put on all around Jan. 10,2003. My driver side door is drooping because it needs a new pin put in. . . My car also seems to balk when I push on the gas peddal,my car also has a popping noise when I hit a hole or turn. When I called the Ford corp. On these issues they seemed liked they really didn't care about any of these things. Maybe you might know someone that I could contact in the Ford corp. That is "high up" and that would listen to my oncerns. Thank you for your time, sincerly, diane.

Intake manifold crossover, as I accelerated the crossover on the manifold ruptured, bursting, massive amounts of coolant to be expelled , causing severe fogging in the interior and exterior of car, coolant on highway interstate, creating a slick surface to other motorist. After contacting and surveying dealers and repair shops in the area, this seems to be a common problem in Ford vehicles with the 4. 6l v8. Ford does have a TSB, has done a recall on police and fleet vehicles, refuses to do consumer automobiles. This is a major problem. Dt.

Consumer states the vehicle overheated and there was loss of coolant while driving, due to a crack in the intake manifold. Dealer and the manufacturer were notified. Feel free to provide any further information.

The plastic intake manifold on these 4. 6l engines crack causing lost coolant. Ford motor company replaces them up to 6 or 7 years on t-birds, mustangs, and police cars and taxi's. Not regular crown vics, grand marque's and town cars. Why. The replacement you buy is inproved with aluminum cooling system passages. The replacement even gives a picture of where to look for the known defect, yet Ford refuses to honor there mistake.

While traveling at 25 mph the temperature gauge went to hot, and consumer could smell antifreeze burning smell. Mechanic stated it was a cracked manifold behind alternater. Please provide any further information.

There is a strong antifreeze smell while driving, then, power steering started slipping. Vehicle was towed to dealer, cracked intake manifold needed to be replaced. Consumer states when pulling over, the engine was steaming from a crack in the intake manifold just behind the alternator, engine coolant was spraying onto the alternator and belt, the coolant leak disabled the power steering unit, the spark plug wires had also been contaminated due to the coolant leak and the thermostat had to be replaced.

My engine coolant leaks out via a cracked manifold intake. It causes the engine to overheat, and has damaged the alternator with leaking coolant.

My engine coolant leaks out via a cracked manifold intake. It causes the engine to overheat, and has damaged the alternator with leaking coolant.

Intake manifold has cracked, allowing water to leak and spray into alternator and destroy it. Manifold needs to be replaced. Also overheating caused transmission to fail, when the manifold leaked out all the coolant, there was no indication of it, because the temperature sensor does not register unless its in liquid.

I had my 1996 Crown Victoria in for its' regular preventative maintenance. My mechanic (whom I have been going to for 15 years) discovered the coolant was low. Upon further inspection; the manifold was found to have a crack in it and was slowly leaking out coolant. This is the original Ford part and is not under a recall at this time. However, upon contacting my Ford dealer - I was informed that this part has been recalled for the police vehicles (same make, model and year). I have been in contact with Ford. They said if there would be a recall, I would be eligible for a refund for this repair. Ford gave me the NHTSA's web site so I can move forward on a recall for this Ford part. This is clearly a defective part - given the low mileage (less than 65,000) of my car. I want to know what else I need to do to pursue a recall for this defective part. Thank you.