Manifold/header/muffler/tail Pipe Problems of Ford Mustang - part 2

The intake manifold on my 1996 Ford Mustang cracked with 48750 miles on the vehicle. This failue occured within a few miles of my home and I was able to limp the car back. This manifold is known by Ford to be defective and was recalled in fleet cars and was also the subject of litigation (which Ford lost). While the manifold on my car is no different than the manifolds on the recalled vehicles or the ones covered by the lawsuit, Ford will not accept responsibility for this failure. While the lawsuit has been settled, and it appears that the lawsuit is costing Ford money, I beg to differ. Their statisticians know the half life of this part. They also know that all cars with this engine will be affected sooner or later. If they make money on unnecessary repairs that are not covered (my parts cost was triple that of what I could have bought the part for online), then they can afford to cover their recalled parts and either break even or worse yet, make a profit off of a manufacturing defect. This sets a poor precidence. Additionally, the manifold leaked for approximately 3 years before the failure. The leak was small, requiring that I add about 2 quarts of antifreeze a year. Vapor from the antifreeze could be smelled inside the cabin of the vehicle from time to time and I'm not sure that this is great for the health of an individual riding in the cabin.

See all problems of the 1996 Ford Mustang 🔎.

I purchased a 1997 Ford Mustang. The 1st intake manifold was replaced on may 19, 2000 and handled under warranty. The 2nd intake manifold failed on September 30, 2005. Ford refused to handle this under warranty and I paid 1187. 07. I believe this should be covered under warranty. Please help me. Thank you.

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My car is losing coolant through a crack in the plastic intake manifold. Ford will not repair it under any warranty. It is a design flaw that Ford should take care of! also my car surges in rpms when first starting and shifting into drive,,,very dangerous!!!!!.

See all problems of the 1999 Ford Mustang 🔎.

A/c condensation drain tube drips on exhaust manifold causing the exhaust to brake. Its an on-going problem that should be corrected. The only remedy is to weld the tube back together. From many shops I've spoken to this is a problem they see and know a lot about.

See all problems of the 2000 Ford Mustang 🔎.

The contact owns a 2004 Ford Mustang. The contact stated that the tail pipe was protruding too far from the vehicle, which caused a massive injury to his son's arm. The tail pipe is cut in a 2. 9 inch edge instead of being rounded. He believed that it should be further back (approximately one inch) to avoid injuries. The failure mileage was 12500 and current mileage was 15,600 updated 01/11/08. Updated.

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1) we purchased a 2004 Ford Mustang convertible. The vehicle was parked in our garage. The exhaust tail pipe has a poor design due to the design cut on the end which leaves two sharp pointed edges like the end of knives. The points are located approximately 1 inch past the bumper. All other vehicles we have seen have rounding tail pipe ends and the ends are flush with the bumper or under the vehicle. 2) the failure of the design of the exhaust tail pipe with the sharp razor cuts leaving two pointed knife like ends and placed past the bumper in the manufacturing process resulted in my three year old having a massive upper arm injury requiring surgery after falling behind the 2004 Ford Mustang. As he fell his right shoulder slid down past the bumper and the pointed sharp edge sticking past the end of the bumper tore into his arm above the elbow to the very top of his shoulder. The injury required many hours of surgery and we hope no other child will have to go through this meaningless design flaw by Ford motor company and their oem manufacture 3) we have tried to correct the problem by asking the Ford dealer for assistance which was refused and reported the injury to Ford executive offices in michigan. Due to non-response by Ford we have placed a normal safe rounded tail pipe extension on the vehicle. The rounding tail pipe is used in all other vehicles that we have seen. The exhaust tail pipe has not been recalled at this time on the Ford Mustangs for 2004 and 2005 which are the same design and placement.

Consumer 1996 Ford Mustang intake manifold cracked and could not be repaired under warranty. The consumer felt that Ford should cover the entire cost of repair plus the monies spent on borrowing vehicles to get to work.

Intake manifold cracked under normal operation with no real reason as to it's failure other than structural flaws in it's original design.

See all problems of the 1998 Ford Mustang 🔎.

1998 Ford Mustang. The consumer states the air intake manifold has cracked. The engine started smoking and the vehicle was running hot. The engine coolant would run out. The vehicle has been looked at by a mechanic and the vehicle has not been fixed. The consumer called Ford. There was a class action lawsuit, if the settlement goes through it will be appealed. Therefore, Ford was not doing anything about the problem.

Consumer states that the plastic intake manifold cracked. As a result, the coolant leaked onto the engine.

1996 Ford Mustang gt convert. Leaking coolant. Took it to the dealership where I service it regularly since 2001. Confirmed a cracked intake manifold. Service department stated there was a recall on this part but it had expired. My wife contacted Ford and they stated it was a courtesy recall and they would not reimburse me because the recall had expired. How can a the manufacturer recall a defective part and then close the date on the recall when there appears to be a continuous problem according to the NHTSA complaints website? cost for replacement intake manifold was $1253. 77. Requesing reimbursement.

1998 Ford Mustang 4. 6 litre. Defective plastic intake manifold split near thermostat housing. Found out through internet research this was a common problem, with recalls to almost every vehicle made with a 4. 6 liter engine except for my year, thus we had to find out the hard way. We now face replacing this part, at our own expense, because Ford refuses to pay for the replacement. We were treated rudely at the local Ford dealership, who even refused to tell us whether a upgraded replacement part was available. Thus the internet research. Thank god for the internet!!.

Intake manifold cracked; I had to pay 589. 17 for a new one and 225. 00 labor charges; I would like a refund.

I have 96 Mustang gt, at 21000 miles intake manifold cracked in the rear , Ford replaced for free, now at 79000k the intake has cracked again in the front , the first time I was told it was a silent recall, before I go back to Ford, again does Ford have to fix it or do I?.

While driving 55 mph the intake manifold split without warning. As a result all the coolant and water leaked from the engine. The cause had not been determined. Please provide additional information.

Coolant was leaking slowly for about eight months, then began to leak a lot the end of December, so the car was undriveable because of risk of overheating, and had to be towed to dealer. It was discovered that the leak resulted from a crack in the plastic intake manifold where the thermostat sits. The dealer replaced the manifold with a new manifold that is metal where the crack occurred (an indication of Ford's awareness of the problem). The cost to replace the intake manifold was $1,070 and I have kept my old manifold. Through my research, I discovered that Ford will replace this part on the 1996-1997 Mustangs and police and fleet cars. A memorandum to the dealerships shows that the 1996-1998 Mustangs have the same intake manifold part number, so Ford should reimburse me for the cost to replace my intake manifold.

The vehicle had steam coming out of engine, which could cause over heating. Owner was informed by the dealer that the intake manifold need to be replaced. Dealer would repair at owner's expense.

Consumer smelled antifreeze. Looked under the hood and discovered a cracked intake manifold. The vehicle was not operable.

Consumer was driving approximately 35 mph when suddenly the head gasket blew out. Antifreeze started to pour out of the muffler.

The intake manifold started leaking coolant, resulting in the windshield to instantly become fogged and unable to see the road. No action has been taken by Ford to correct the problem of my vehicle.

(1) Ford made the intake manifold out of plastic. (2) manifold cracked, and caused loss of engine coolant. (3) replaced manifold. Old part is available. Notes: new one is made of aluminum in crack area! Ford has issued a recall but only for fleet vehicles. Internet is full of like stories.

I currently own a 1998 Ford Mustang gt. It has approximately 90,000 miles on the engine. Iam the srcond owner. It has the 4. 6 v-8 engine. At approximately 88,000 miles the intake manifold developed a crack and started leaking antifreeze. It has continually gotten worse and is now to the point that the vehicle is inoperable. I contacted Ford customer service on 12/27/2004 regarding 3 customer notification letters I found on line regarding the intake manifold failures and was told that my VIN #'s were not involved in the recall for replacement. I have also learned that this is very common failure. I contend that Ford should replace all defective intake manifolds as they occur instead of designating only certain VIN #'s as a failure is a failure.

(1) events leading up to the failure: Ford poorly designed an intake manifold so that the coolant running through it actually eats away the plastic. (2) failure and its consequences: the intake cracked and sprayed coolant throughout the engine bay. This rendered the car undriveable. (3) what was done to correct the failure: nothing was done to correct the failure. Ford has a program (97m91) wherein when the part fails(regardless of mileage), the dealership will repair it at no cost to the customer. This program stated that it was covered from 7 years of the start of the warranty of the vehicle. My intake manifold failed at 7 years and 59 days with only 23000 miles on the car.

I have a 1998 Ford Mustang gt. The plastic intake manifold valve has cracked and will have to be replaced. I have done quite a bit of interent research and found this seems to be a known issue with this plastic part that Ford refuses to do anything about.

Hello, my Ford Mustang overheated and developed a crack in the air intake manifold which resulted in engine coolant leak and it had to be replaced. I read that a recall on this part that was called by Ford because the same exact engine on the crown victoria gives the same problems and a recall is in effect on it. Why would they not have a recall on all engines if it is ecactly the same? I would honestly appreciate an answer if it can be provided. Best regards. Munazzar tapal.

While driving at 45 mph vehicle overheated. Vehicle was taken to the independent shop, and mechanic determined that intake manifold cracked, and coolant spilled inside the engine.

While driving vehicle overheated on its own. Vehicle hesitated while accelerating, then stalled. Consumer was unable to restart vehicle, and had the vehicle towed to dealer. Mechanic determined that the intake manifold needed to be replaced. This vehicle was not recalled by VIN or under warranty. Consumer informed the mechanic that part number f8a2-9424-bc, notification #97m91 for intake manifold was recalled. Mechanic insisted that recall was not for this vehicle.

I have a 1998 Ford Mustang. I now have a cracked intake manifold. Ford motor company knows that the intake manifolds are subject to failure. They also recalled some of the vehicles with the same intake manifold that I have in my car. I was told, by Ford that since my car was made a few months after those being recalled that I do not qualify. The part in question is an intake manifold made out of plastic. The manifolds that were replaced by Ford now have aluminum in place of the plastic in the area of the crack. I learned of a Ford document # 97m91 which shows that Ford knows of the problem. I need to know what I can do to try and get Ford to fix this problem.

Intake manifold cracked. Was told new one was redesigned. Spoke with several auto parts dealers and found this component breaks in same location on all. This is a manufacturer defect and Ford will not replace for free outside of warranty.

Plastic intake manifold cracked. Happens on most 1996-1998 Mustang gt 4. 6. New part from Ford replaces plastic part prone to cracking with aluminum part. Ford has a service program # 97m91 related to 4. 6 engines for cars built 07/1995 - 06/1997. Cars built after this end date still experience problems due to defective part.

My 1998 Ford Mustang gt with a 4. 6 liter engine suffered a cracked intake manifold which was replaced costing approximately $600,00, has cracked once again. I have contacted numerous Ford dealerships about the problem, to which they replied it is not their problem. I feel that something that has been recalled on other similar vehicles should also be recalled and replaced with a working part on mine.

While driving 40 mph consumer noticed fluid leaking from underneath the vehicle. Consumer was able to maintain control of vehicle, and drove it to the dealer for inspection. Mechanic determined that intake manifold needed to be replaced due to a blowout.

While driving the vehicle at 60 mph started to smell anti-freeze. When I checked the engine compartment. I found that the left side of the plastic, intake manifold had cracked an was leaking anti-freeze. Contacted dealer, they wanted $580 for a new manifold plus labor to put it on. I feel that if a manufacture puts an intake manifold on on of thier vehicles it shoud last for the lifetime of the vehicle and should not have cracked, I think this is poor enginering, and should be replaced free of charge by the dealer, since Ford has replace all police vehicle intakes.

While driving the intake manifold blew. This problem was caused by antifreeze leaking from the intake manifold. Smoke started to accumulate inside the vehicle from the a/c vents. The dealership was notified, but did not resolve the problem.

Dear Ford motor company, will you please assist in getting my cracked intake manifold fixed? I am under the impression that there once was a recall on the plastic intake manifolds but I never heard anything about it. Now I find myself in the position of needing mine replaced as it is cracked. Thank you so much for your future assistance, as I know you wish to keep your consumers happy and loyal and, most importantly, you want to provide the consumers with products that work without manufactures defects so that we may transport your future car buyers safely. Sincerely, j. Herndon.