Nine problems related to manifold/header/muffler/tail pipe have been reported for the 1996 Mercury Cougar. The most recently reported issues are listed below.
Tl * the contact owns a 1996 Mercury Cougar. The contact stated that the vehicle was leaking anti freeze abnormally. The vehicle was taken to a local repair shop where the contact was advised that the plastic intake manifold was fractured and would need to be replaced. The vehicle was not repaired. The manufacturer was not contacted to report the failure. The failure and current mileage was 140,000.
While driving my 1996 Cougar this past September, which has only 40,360 miles on it and is stored most of the year for the purposes of collecting and preserving the vehicle indefinitely, at low speeds I noticed the obvious sign of coolant and the smell of coolant coming from up under the hood. I then shut the vehicle down right away and discovered coolant running onto the ground below. Now, being of an experienced nature with automobiles and using close observation of the problem it appeared to be emanating from the front of the intake manifold. I then discovered after the fact that these 4. 6 liter engines are notorious for this intake cracking problem, so now I will be purchasing an upgraded and improved intake for around $223. 00 that is designed as a replacement for this defective manifold. I then had my vehicle towed to my place of residence at the cost of around $100. 00 question is? why then am I one of those owners that were not given the opportunity to get a covered replacement when it is very apparent that my year 1996 Mercury Cougar should have been included in the 4. 6 engines recall. This could have been a disastrous situation damaging or shortening the life of a well cared for engine. The intake manifold is simply not a component that should fail, I realize that this doesn't apply to every component on a vehicles engine but it does and should apply to this component because of the importance of this part, since the potential cost incurred to an owner if it overheats the engine could be quite high and this is completely solvable by proper component design as is well proven with good designs in the many automobles produced in past years.
I purchased my Cougar in 1996 brand new. I have been it soul owner since the date of purchase. On November 23, 2004 I was driving to work and about half way there my low coolant light came on. There was no other signs that my car was in trouble, no overheating on my temperature gauge, so I continued to work, parked the car. Before I started the car I added a gallon of antifreeze and it seemed to drain out so I added another gallon, it did the same. I immediate called my mechanic before starting the car. He told me to start the car and when I did I looked under the car and all the antifreeze was pouring out fast. I shut off the car and had it towed directly to my mechanic. He has informed me that the manifold has cracked. I have had this item periodically checked since I received the recall information in 1998. Each check has assured me that this manifold was in good shape. Now I find out that the recall will not cover the replacement of the manifold. This is going to cost me $1100. 00 to fix. I think it is very unfair that Ford will not continue to honor the recall since they know that this plastic manifold will not hold up for the life of the car. This is my first major issue and I am very disappointed in fords policy. I bought my Cougar in good faith and I love my car very much. Because I take care of my vehicle I missed the cutoff time by four months and now it will cost me dearly. Why weren't vehicle owners informed of the cutoff times? I was given the impression this recall would be honored in good faith for the life of the vehicle.
Intake manifold has developed a crack. As a result, water leaked out, and the engine overheated.
Intake manifold cracked. Made of a plastic material. Is there any recalls out there for this? if not, why not? why would you put plastic material in the engine?.
Intake manifold is made of plastic. There was a failure in the plastic material on the water cross-over jacket (portion of the manifold). This caused all the coolant to flood out. I found Ford had issued a TSB (97m91) throgh its owners notification program (onp) identifying fatigue and failure of this part. A new part had been designed by Ford engineers that used an aluminum coolant cross-over jacket rather than the plastic. The onp TSB was released in 1999. I called the support phone number, 1-800-392-3673. Is now the claims number. However, he indicated the VIN number still showed the previous owner. This was promptly changed. It turns out the 7 year extended warranty issued by Ford (to all new and subsequent owners) had expired in may of this year. Hear is my problem: 1. I bought the car(used) from a major dealer in March of 2002. Why did Ford not have my owners information? what good is the onp if it is inaccurate? 2. I had to do an extensive search to find this TSB 97m91. Had I known about this, I would of had it replaced before it failed, or had it periodically inspected. . I was never given the opportunity to make that descision. 3. It seems the owners notification program only benefits those who are "in the computer system". 4. I feel I have no recourse to negotiate with Ford. The claims phone number offered no assistance to this inquiry. 5. This is a poorly designed part. So poor, Ford issed a 7 year extended warranty. What makes them feel they have no obligation to its consumers even after 7 years? this is a major system component. It should have a reasonable life expectancy. It would not be considered acceptable to crack an engine block, head, transmission bellhousing. So why is it accepted that 7 years is acceptable for an intake manifold? it is not normal to have a 3 inch fatigue crack in an intake manifold. I feel Ford should include my vehicle in a mandatory recall of this part.
Tear along front face of upper intake manifold. Called several salvage yards to find replacement and was told by all that they can't keep these in stock. When I did locate one the manager at the salvage yard asked what happened to my intake. I showed him where the intake split open and he informed me that they're seeing a lot of these with the same problem and I was lucky to find the one he had. This plastic (composite) component probably doesn't fair well in arizona. Dt.
Check for coolant leak at intake manifold. Replaced intake manifold. There were regular oil changes and tire rotation. The engine light had come on, and the coolant light would come on and off. The dealer had to replace the engine sensor light and added a cup of water. The consumer's son in law was driving the vehicle and white smoke coming from under the vehicle, the rubber strip on the inside of the vehicle was coming off, the right rear trim panel coming loose, the brakes made rubbing noise intermittently, glove box door won't shut, the air bag would rattle, the right front door rattled while the vehicle was in motion, and the door switch trim panel was discolored.
Intake manifold is made of a composite material the heat of motor must have cracked it, the crack is right behind where the alternator sits. So, it is on the front of the intake. Why is an intake made of plastic anyway?.