Manifold/header/muffler/tail Pipe problems of the 2002 Ford Escape

While starting the engine after overnight parking, a loud explosion was heard and white smoke was seen coming from under the hood. The ignition was immediately turned off. Examination of the engine revealed a damaged decorative cover over the intake manifold and shattered intake manifolds. Two spark coils were later found to be damaged by the explosion. The heads were reconditioned as ignition leakage thru the unseated valves was a factor contributing to the ignition of the residual gases in the intake manifold. Secondary contribution was the original intake manifold was of an old style and not capable of withstanding the backfire force. A new, modified composite intake manifold was available but not on a recall.

While driving on i294 northbound between 127th street and approximately 103rd street, the engine on our 2002 Ford Escape blew up. There was no warning in terms of warning lights or other indicators that there was any problem. Shortly after entering the interstate, the car began to make a motor boating type of sound. It sounded as if the sun roof was not completely closed. Thereafter the engine blew and pieces began to fly out. A huge fireball, hot enough to melt the license plat holder in the middle of the tailgate was discharged from the tailpipe. The car began smoking and smoke was discharged into the cab of the vehicle. We were able to make an emergency stop on the shoulder of the road. The car continue to smoke and there was oil leaking from the engine. A piece of the crankshaft was found on the shoulder of the road 100-150 feet behind the vehicle. The fireball had been of sufficient size to cause multiple calls to local fire department as well as the state police.