Two problems related to manifold/header/muffler/tail pipe have been reported for the 1998 Ford Taurus. The most recently reported issues are listed below.
Heat/vibration of engine caused plastic vacuum elbow to break. This caused loss of vacuum to brake booster and loss of brakes. Customer ran into brick wall. We are vehicle investigators/engineers for insurance companies. Normal vibration and heat caused this failure. I would recommend some kind of strain relief or a superior material for this important part. This elbow connects main manifold vacuum to a vacuum manifold mounter on left side firewall. This manifold feeds the vacuum systems for the vehicle and the power brake booster (bosch unit). Resultaing in loss of manifold vacuum caused the engine management system to surge and idle poorly. There were no broken or fatigued engine mounts to cause unwarranted stress on this plastic elbow. It appears that plastic elbow is made from pvc. I would recommend either steel, brass, or a polyolefin based composite be substituted for existing materials used. ---thank you, greg barnett note: credentials available upon request .
Exhaust problems with 1998 Ford Taurus. Nar 07092003 Ford dealer was notified about replacing the defective part, however they refused to replace it. The consumer hoped that a national recall would be initiated to inspect the potential deadly conditions.