Manifold/header/muffler/tail Pipe Problems of Ford Thunderbird - part 1

The contact owns a 1996 Ford Thunderbird. The contact was driving 30 mph when he noticed an abnormally strong coolant odor. The contact then inspected the vehicle and found that the antifreeze intake manifold had failed. The intact manifold was cracked and causing antifreeze to spill. The vehicle was not taken to the dealer to be diagnosed or repaired. The failure and the current mileage was 60,000.

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The plastic intake manifold on my 1997 Ford Thunderbird cracked spilling out all my coolant and causing my engine to overheat, this is a design flaw that should be coverd by Ford motor company, this happend while driving down gratiot Ave. In roseville mi at 40 miles per hour with no previous warning, this failure happend 7/3/2011 Saturday over the forth of July weekend, where I couldn't get it to a open Ford dealership, now I connot use my vehical for work Monday 7/4/2011. Will this repair be coverd by Ford motor company?.

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I have a 1997 Ford Thunderbird that has a manifold problem. I am being told by Ford that it doesn't fall under the recall from 2005 because it wasn't built in the right plant. I have read a lot of information that all of the 1997 t-bird have this problem and need to be fixed. Not only is does my car not run right, but I also am not facing replacing my catalytic converter, as well due to the leakage. We are talking about $1700 in repair.

When I bought the car, a year ago, it ran great. One day as I as coming up a hill, my car started shaking. It was a cracked intake manifold, that of which Ford was in a class action lawsuit in 2005. Which covered a "select few" of Thunderbirds. However now that my manifold cracked, there "not at fault. " we had the car fixed, only to learn afterwards that Ford had several issues about the faulty intake.

The contact owns a 2002 Ford Thunderbird. While driving 5 mph, the service engine light illuminated after the vehicle had been serviced for its 30,000 mile routine maintenance. The dealer stated that the manifold gasket leaked oil onto the coils and spark plugs. All of the failures needed to be repaired. The failure mileage was 76,000 and current mileage was 76,050.

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The contact owns a 1997 Ford Thunderbird. While driving 40 mph, in heavy traffic the contact noticed smoke rising from under the hood. The temperature gauge needle shifted to the hot indicator. The vehicle was towed to the repair shop and the mechanic stated that the engine was leaking coolant and the plastic intake manifold was cracked. The powertrain was unknown. The current and failure mileages were 73,500. *updated 12/12/07 updated 12/12/07.

Defective intake manifold. Ford replaced once, free of charge @ 48,523 miles. Cracked again @ appx. 95,700 miles. Ford refused to replace free of charge. Replaced one defective manifold with one that was just as defective. There was a class action suit on this manifold, it was so bad.

The contact's daughter owns a 1997 Ford Thunderbird. While driving 55 mph, the vehicle overheated and the contact noticed that antifreeze was leaking. Her daughter noticed a crack on the intake manifold, which she believed may be the cause of failure. As of August 31, 2007, the dealer has not inspected the vehicle. The failure mileage was 57,000 and current mileage was 60,000.

- the contact wanted to have repair done to 1996 Ford Thunderbird, however service bulletin #97m91, dated Jan 19, 1998 (NHTSA item number: 605621) expired and Ford charged for the repairs. The mileage at the time of the failure was 80000. The contact said that the service bulletin was for the intake manifold. The contact wrote to Ford. The refused to honor the service bulletin. Updated 2/6/2007 -.

Defective intake manifold on 1996 Ford Thunderbird. The car only has 84,450 miles on it! cost was $1002. 02 to repair. Why is the consumer being charged for this costly repair when this is a known defective part from the Ford motor company?.

Intake manifold cracked causing coolant to leak out. Ford will not repair unless I pay for it. Class action law suit pending. Ford agreed to replace on vehicles 7 years old or less. My veh is 8 years old with 26000 miles. Bad design for intake.

Intake manifold cracked. This part was made out of nylon and is a known defective part installed at the factory. Ford motor company refused to reimburse stating that there was a customer satisfaction action in 1996. Since the problem was due to a known defectivepart I think it should be covered for life of the vehicle. Later Ford redisigned the part using aluminum instead of nylon.

Upper intake manifold on my 1997 4. 6 l Thunderbird cracked and blew all the coolant into the engine compartment. I had to pay Ford to replace the upper intake and the plugs that were fouled out. They refused any responsibility even with a formal written complaint to their home office. It is my understanding this is happening to a lot of their 4. 6 l engines in a variety of vehicles.

Plastic intake manifold failure on a 1996 Ford Thunderbird v8. Part failure was preceded by a "check engine light" and "low coolant" light. Turns out that Ford had put out "service bulletin" in 1999 and followed up on it in 2001 on this issue (97m91) yet they never notified any owners. Cost of repairs for this part will be around $1,000 yet Ford will not do anything willingly to rectify the situation. Failure of part could lead to catastrophic engine failure if not corrected.

While driving approximately 40 mph consumer heard a noise, then water spilled from the engine. Vehicle was taken to the dealer for service, and it was determined that intake manifold cracked.

1997 Ford Thunderbird lx v8 4. 6 liters. 1997 Ford Thunderbird lx had a coolant leak. The plastic intake manifold overheated. Could smell antifreeze when getting out of vehicle. The antifreeze was leaking in three places. Vehicle had the original parts. The consumer was the second owner of the vehicle. Had not contacted the manufacturer. Did have someone look at vehicle , who confirmed that the intake manifold was plastic and vehicle was leaking antifreeze, and that the o rings needed to be replaced. Manufacturer was aware of this problem. The consumer found on the internet that a technical service bulletins was sent out on February 2, 2002 discussing this problem. However, the consumer was unaware of the technical service bulletin.

1996 Ford Thunderbird 4. 6l 281cid v8 motor failure of plastic intake manifold. Driving home under normal conditions and check coolant light came on. Wife said she had thought she smelled burning coolant for several days prior. Took to mechanic and he pointed out the crack in the intake manifold. Said this was a very common problem with this motor. Paid over $800. 00 to have repaired with upgraded part. Ford motor CO. Has been aware of problem for years and issued a recall for taxis and police vehicles but recall does not cover privately owned vehicles. Car has approximately 114,000 miles.

The intake manifold cracked, loss of all antifreeze and vehicle being towed to dealership. Vehicle only has 60,000 miles on. The letter from Ford to replace this expired in may 2004! I had complained to my dealership about loss of antifreeze, gas, they found no problems. Of course, now I have to pay for the entire repair. Even though I see that many t-bird owners are having the exact problem. This should have been a mandatory recall from Ford. Because existing problems are being reported!.

I was told that their is a recall on my 1996 Ford Thunderbird for a faulty intake cooling manifold. Can you please confirm this. I do not see it on your recall list.

The intake manifold was defective. All of the coolant leaked and subsequently the vehicle was towed. The dealer stated the defect was outside of the seven years of the original recall.

While driving consumer noticed smoke coming from the front of the vehicle. Consumer was able to maintain control of the vehicle, and drove it to a body shop. Mechanic determined that the intake manifold was cracked and needed to be replaced.

1996 Ford Thunderbird 4. 6l v8 motor failure of plastic intake manifold. Driving home under normal conditions and check coolant light came on. Duaghter said she had thought she smelled burning coolant for several days prior. Took to mechanic and he pointed out the crack in the intake manifold. Said this was a very common problem with this motor. Paid over $900. 00 to have repaired with upgraded part. Told by mechanic that recall issued but expired about 6 months prior to repair.

I was driving my car to pay the power bill. I had made a complete stop and then turned left up the road about 4/10's of a mile when I pulled into the parking space I noticed white steam coming from the engine compartment. I opened the hood a the engine was covered in antifreeze. I called for a tow hoping it was a blown hose or at worst a head gasket. So I didn't drive it further to prevent further damage. The dealership looks at it and says it is a cracked intake manifold. Which leads to a $1135 bill for parts and labor. Some online research brought a concern. . . Is the intake manifold plastic? if so, why!?.

I am the original owner of a 1997 Ford thunder bird with the 4. 6 engine. The intake manifold is cracked . I have been informed this is a recalled part on some cars but it seems my car is not included in the recall. The original repair part is not available any long do to the flaw. Since this is the case it woud seem to me all vehicles with this intake manifold would be included in the recall.

In febrruary 2003, my 1996 Ford Thunderbird 4. 6l started spewing what I thought was smoke from the engine compartment. I was just at my driveway and pulled in. After opening the hood I realized it was not smoke but coolant that was being sprayed all over the hot engine. I had the car towed to friendly Ford in las vegas, nevada, where I had bought the vehicle, and after some discussion, they replaced the intake manifold under a TSB. On 6-2-04, some 16 months later, the intake is again leaking. After doing some research, I found that the part they put on the car is not the recommended part as stated in a letter from Ford motor company in flint, michigan,dated December 2001. The part which Ford states is the replacement part is f6az9424aa. The part listed on the repair invoice is f8az8424aaa. The part actually installed on the car has a part number of ae9424ca. I talked to the service manager, dennis eich, at friendly Ford on 6-22-04, who stated that the part number doesn't matter, they don't need to install the part recommended by Ford in the letter, and because the part is out of warranty now they won't fix it correctly. I unfortunately am not alone in this problem. My research, via the internet, shows numerous complaints of the same problem. This is a manufacturers defect which should be subject to a full blown recall and Ford should be required to repair the vehicles with the recommended parts.

Coolant fumes/odor was coming inside the vehicle while driving at any speed. Consumer inspected the vehicle and found a crack in the intake manifold. Consumer notified the dealer, who informed the consumer that this vehicle was not covered under a present recall.

Intake monifold failed to contain 220 degree f engine coolant.

The consumer's 1996 Ford Thunderbird completely broke down due to the failure of the plastic intake manifold. The vehicle was purchased new and the consumer wasn't given prior warning that this existed. The defective part was on the vehicle between the dates of may 1996 and February 2004. The manifold was found cracked. Ford motor issued program #97m91 in re to vehicles built with the plastic manifold. The consumer requested reimbursement.

Cracked plastic intake manifold that caused a major coolant leak.

Defective plastic intake manifold. Never notified of any recall concerning defective intake manifold. Ford says it's not covered. I paid to have it fixed and they replaced it with another plastic intake manifold -- the link below shows over 250 other consumers complaining about the same thing. . Read more...

Engine developed a coolant leak due to a split in the plastic intake manifold. Recall 97m91 which is only good for 7 years from the start of the original warranty was up 2 days prior to incident. Fomoco and dealer wouldn't cover, to bad for me. Recall doesn't cover replacement unless it is leaking within that 7 years. Design has been changed to an aluminum crossover that hopefully wont split and costs approx $800 to fix.

My complaint is about the cracked intake manifold currently sitting in my 1996 Thunderbird 4. 6l although I can find only a little bit of information on this matter regarding recalls; class action suits; and free of charge replacements; I am very interested in finding out if there is actually anything like that happening and to file my complaint and/or join any other consumer who is having the same problem on any class action suit.

The plastic intake manifold cracked which caused coolant to leak and the vehicle over heated.

The consumer could smell anti-freeze in the cab of the vehicle. The mechanic stated that the intake manifold was cracked in two spots.

Intake manifold is leaking coolant onto the engine. Thid could result in an engine fire.