Bulletins
| Bulletin | Bulletin date | Replacement Bulletin | Item no. | Summary | Added |
|---|---|---|---|---|---|
| ENGINE AND ENGINE COOLING | |||||
| 18351 | 12/01/2004 | 10014620 | Charging system limitations. *eh | 05/05/2005 | |
| 0222 | 02/04/2002 | 630628 | Some vehicles may exhibit an intake manifold crossover (first runner) coolant seepage condition. *tt | 04/19/2002 | |
| ENGINE AND ENGINE COOLING - ENGINE | |||||
| 07212 | 10/01/2007 | 10023943 | Some 1997-2008 vehicles equipped with a 4.6l 2v, 5.4l 2v, or 6.8l 2v engine--spark plug thread repair procedure--not covered under new vehicle limited warranty. *nj this includes f-53 motorhome chassis. updated 2/23/10. *pe | 02/20/2008 | |
| 03206 | 10/13/2003 | 10004889 | Some dedicated cng vehicles may exhibit various driveability conditions due to a loss of injector performance, resulting from fuel quality. loss of power at heavy load, diagnostic trouble codes (dtcs) for lean fuel, rough idle, hard start, | 01/14/2004 | |
| 9811483 | 04/01/1998 | 613394 | Some police and export cars equipped with phonelic piston calipers may exhibit brake squeal from the rear when braking. *tt | 07/11/2000 | |
| 9947 | 03/08/1999 | 604763 | Engine experiencing roughness at idle due to exhaust system resonance. *tt | 05/12/1999 | |
| 9874 | 04/13/1998 | 601343 | A new silicone gasket and sealant. *yc | 07/24/1998 | |
| ENGINE AND ENGINE COOLING - ENGINE - GASOLINE | |||||
| 15761 | 03/01/2002 | 636408 | Some dedicated cng vehicles may exhibit driveability conditions of hard start / no start / rough running. *tt | 11/08/2002 | |
| 01246 | 12/10/2001 | 630515 | Engine oil system priming procedures, service tips for reports of premature engine failure. *tt | 04/18/2002 | |
| 0214 | 01/21/2002 | 630001 | Some engine assemblies with aluminum cylinder heads repaired in-vehile have been found to leak coolant and/or oil from the cylinder head gasket area. *tt | 04/11/2002 | |
| 01205 | 10/15/2001 | 627927 | Some vehicles may exhibit vacuum or air leaks in the intake manifold and / or engine system causing diagnostic trouble codes p0171 and or p0174. *tt | 02/26/2002 | |
| 15158 | 08/01/2001 | 624571 | Some vehicles may exhibit a fead belt jump-off toss. *yh | 11/07/2001 | |
| 0147 | 03/05/2001 | 619424 | Subject regarding engine oil recommendations for use in 2001 vehicles - sae 5w-20 motor oil. *tt | 05/30/2001 | |
| 12174 | 11/01/1998 | 613224 | Some vehicles may exhibit a hard start/long crank, cold start stall, cold rough idle concern. *mjs | 06/19/2000 | |
| 983107 | 02/25/1998 | 607401 | Brief information regarding engines being added to the fqr (ford quality renewal) assembly program. *tt | 09/22/1999 | |
| 99816 | 05/03/1999 | 606420 | Ford motor company now recommends sae 5w-30 viscosity grade for servicing any ford gasoline-powered vehicle regardless of model year. *tt | 08/19/1999 | |
| 9947 | 03/08/1999 | 604763 | Engine experiencing roughness at idle due to exhaust system resonance. *tt | 05/12/1999 | |
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM | |||||
| 8300 | 04/01/2000 | 613634 | Some vehicles may exhibit a bang / popping noise heard from the exhaust system during cool-down. **mr | 07/26/2000 | |
| 13025 | 07/01/1999 | 610768 | Some vehicles may exhibit a bang popping noise heard from the exhaust system during cool-down. *tt | 05/12/2000 | |
| 982010 | 10/12/1998 | 603695 | Experiencing a buzzing or rattling noise from the exhaust system. *yc | 03/02/1999 | |
| 9864 | 03/30/1998 | 601312 | Information on a buzzing or rattle noise from the exhaust system. *tt | 07/21/1998 | |
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL | |||||
| 982310 | 11/23/1998 | 603724 | Mass air flow (maf)- sensor contamination- service tip. *ak | 03/03/1999 | |
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL - CATALYTIC CONVERTOR | |||||
| 03245 | 12/08/2003 | 10008275 | Malfunction indicator lamp (mil) on with diagnostic trouble codes (dtcs) p0420 and/or p0430. *tt | 07/26/2004 | |
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - MANIFOLD/HEADER/MUFFLER/TAIL PIPE | |||||
| 05N04 | 12/14/2005 | 10018959 | Extended coverage program 05n04 - extended coverage for composite intake manifold. this program is being provided as a settlement to a class action lawsuit. the terms of the settlement extend the coverage of the all-composite intake manif | 01/25/2006 | |
Investigations
| NHTSA ID | Manufacturer | Date open | Date close | Subject | Recall campaign | |
|---|---|---|---|---|---|---|
| ENGINE AND ENGINE COOLING | ||||||
| DP05005 | FORD MOTOR COMPANY | 09/22/2005 | 01/04/2006 | SPARK PLUG EJECTION FROM CYLINDER HEAD | ||
| On september 6, 2005, odi received a petition requesting that the agency investigate allegations of engine spark plug ejection in certain model year 1997 through 2004 ford vehicles with triton v-8 and v-10 engines.odi received a total of 474 non-duplicative complaints on the subject vehicles where the complainant, or the dealer repairing the vehicle, reported that a spark plug detached from the cylinder and/or ejected from the engine.as of december 8, 2005, odi is not aware of any allegations where the alleged defect resulted in a loss of vehicle control, a crash, an injury, or a fatality in any of the 10,319,810 subject vehicles.in addition, odi is aware of only two incidents where the vehicle stalled without restart.information contained in the odi consumer complaints and obtained from 72 telephone interviews with complainants showed the following:(1) 99% of the complaints were on my 1997 to 2002 subject vehicles.(2) most the complainants reported hearing a loud pop while driving or upon starting up the vehicle followed by a loud, repetitive clicking or popping sound.(3) many of the complainants reported that the popping sound was accompanied by some loss of vehicle power; however, in 99% of the incidents reported, the vehicle did not stall.in the very few incidents where the vehicle did stall, most vehicles could be restarted.(4) only a small percentage of the complainants cited that they smelled gas or a slight burning smell when the incident occurred.(5) in all but a very few incidents, vehicle damage was limited to the engine.in one incident, the complaint reported that the fuel rail was damaged and replaced after one of the spark plugs ejected from the engine; however, the complainant reported that the damage did not result in any type of fuel leak or fire.in another incident, the only incident where a fire was alleged, the complainant reported that no fluid leak was observed, but that a fire resulted after the spark plug had ejected from the engine and he had restarted the vehicle and driven to another location.none of the complainants reported any damage to the vehicle hood.(6) only two complainants reported that they observed what appeared to be some drops of fuel coming from the cylinder where the spark plug had failed or on the spark plug itself; however, each of these complainants reported that there was no smoke or flames as a result of his incident.as the petitioner noted, and odi | ||||||
| EA02025 | FORD MOTOR COMPANY | 09/06/2002 | 06/30/2004 | SPEED CONTROL DEACTIVATION SWITCH FIRES | ||
| Based on the low rate of fire incidents (2.5 incidents per 100,000 vehicles sold) where failure of the scds is involved and the age of the vehicles | ||||||
| ENGINE AND ENGINE COOLING - ENGINE | ||||||
| DP05005 | FORD MOTOR COMPANY | 09/22/2005 | 01/04/2006 | SPARK PLUG EJECTION FROM CYLINDER HEAD | ||
| On september 6, 2005, odi received a petition requesting that the agency investigate allegations of engine spark plug ejection in certain model year 1997 through 2004 ford vehicles with triton v-8 and v-10 engines.odi received a total of 474 non-duplicative complaints on the subject vehicles where the complainant, or the dealer repairing the vehicle, reported that a spark plug detached from the cylinder and/or ejected from the engine.as of december 8, 2005, odi is not aware of any allegations where the alleged defect resulted in a loss of vehicle control, a crash, an injury, or a fatality in any of the 10,319,810 subject vehicles.in addition, odi is aware of only two incidents where the vehicle stalled without restart.information contained in the odi consumer complaints and obtained from 72 telephone interviews with complainants showed the following:(1) 99% of the complaints were on my 1997 to 2002 subject vehicles.(2) most the complainants reported hearing a loud pop while driving or upon starting up the vehicle followed by a loud, repetitive clicking or popping sound.(3) many of the complainants reported that the popping sound was accompanied by some loss of vehicle power; however, in 99% of the incidents reported, the vehicle did not stall.in the very few incidents where the vehicle did stall, most vehicles could be restarted.(4) only a small percentage of the complainants cited that they smelled gas or a slight burning smell when the incident occurred.(5) in all but a very few incidents, vehicle damage was limited to the engine.in one incident, the complaint reported that the fuel rail was damaged and replaced after one of the spark plugs ejected from the engine; however, the complainant reported that the damage did not result in any type of fuel leak or fire.in another incident, the only incident where a fire was alleged, the complainant reported that no fluid leak was observed, but that a fire resulted after the spark plug had ejected from the engine and he had restarted the vehicle and driven to another location.none of the complainants reported any damage to the vehicle hood.(6) only two complainants reported that they observed what appeared to be some drops of fuel coming from the cylinder where the spark plug had failed or on the spark plug itself; however, each of these complainants reported that there was no smoke or flames as a result of his incident.as the petitioner noted, and odi | ||||||
| ENGINE AND ENGINE COOLING - ENGINE - GASOLINE | ||||||
| DP05005 | FORD MOTOR COMPANY | 09/22/2005 | 01/04/2006 | SPARK PLUG EJECTION FROM CYLINDER HEAD | ||
| On september 6, 2005, odi received a petition requesting that the agency investigate allegations of engine spark plug ejection in certain model year 1997 through 2004 ford vehicles with triton v-8 and v-10 engines.odi received a total of 474 non-duplicative complaints on the subject vehicles where the complainant, or the dealer repairing the vehicle, reported that a spark plug detached from the cylinder and/or ejected from the engine.as of december 8, 2005, odi is not aware of any allegations where the alleged defect resulted in a loss of vehicle control, a crash, an injury, or a fatality in any of the 10,319,810 subject vehicles.in addition, odi is aware of only two incidents where the vehicle stalled without restart.information contained in the odi consumer complaints and obtained from 72 telephone interviews with complainants showed the following:(1) 99% of the complaints were on my 1997 to 2002 subject vehicles.(2) most the complainants reported hearing a loud pop while driving or upon starting up the vehicle followed by a loud, repetitive clicking or popping sound.(3) many of the complainants reported that the popping sound was accompanied by some loss of vehicle power; however, in 99% of the incidents reported, the vehicle did not stall.in the very few incidents where the vehicle did stall, most vehicles could be restarted.(4) only a small percentage of the complainants cited that they smelled gas or a slight burning smell when the incident occurred.(5) in all but a very few incidents, vehicle damage was limited to the engine.in one incident, the complaint reported that the fuel rail was damaged and replaced after one of the spark plugs ejected from the engine; however, the complainant reported that the damage did not result in any type of fuel leak or fire.in another incident, the only incident where a fire was alleged, the complainant reported that no fluid leak was observed, but that a fire resulted after the spark plug had ejected from the engine and he had restarted the vehicle and driven to another location.none of the complainants reported any damage to the vehicle hood.(6) only two complainants reported that they observed what appeared to be some drops of fuel coming from the cylinder where the spark plug had failed or on the spark plug itself; however, each of these complainants reported that there was no smoke or flames as a result of his incident.as the petitioner noted, and odi | ||||||
Consumer Complaints
| Fail date | miles | occurences | Purchase date |
|---|---|---|---|
| ENGINE AND ENGINE COOLING | |||
| 11/23/2010 | 97500 | ||
| While driving in nj, the manifold blew and made the vehicle inoperative. luckily, my mechanic came and towed the car to his garage. the mechanic performed a pressure test and determined that the 'plastic manifold' had blown. the origin of the fluid leak was behind the alternator. then we did some research and found out that this was a problem back in 2004-5. i never knew, nor was i notified about this problem. i am the original owner of the car. the car was just into the ford dealership to diagnose a check engine light on, no discussion was made about this manifold problem ... they even checked for any previous technical bulletins. so, now what happens? | |||
| 06/10/2010 | 90000 | ||
| I own a 1997 crown vic less than 100 thousand miles. bought the car 2 years ago at dealership in louisville ky. found out there was recalls on vehicle after purchase was told carmax was good. now here i sit with a cracked intake manifold which was recalled, but noone every fixed it. someone should be responsible for this, yes was a recall shouldnt there be a law to make someone stand behind the crack intake manifold this was a 1 owner when i bought it with only like 60000 miles, | |||
| 12/28/2008 | 201000 | 1 | |
| While checking the oil in the car, we noticed a crack in the intake. i was wondering if there has been a recall for this problem like with the firebird intake recalls. *tr | |||
| 07/28/2008 | 91000 | ||
| Tl*the contact owns a 1997 ford crown victoria. while driving approximately 45 mph, the engine warning light illuminated on the instrument control panel. the engine then began to overheat. the contact pulled over to further inspect the vehicle and noticed steam near the engine. the vehicle was towed to a dealer and they stated that because the intake manifold was made out of plastic, it failed. the contact would have to pay over $3,000 to have the engine replaced. the vehicle has not been repaired. the failure and current mileages were 91,000. | |||
| 06/01/2008 | 65500 | 1 | |
| I recently determined that i now have a leaking front cover/intake manifold gasket/cracked intake manifold on my 1997 ford crown victoria 4.6 liter v-8 which will require immediate repair. had this defect manifested itself back in 2005, i would have been covered by the chamberlan v. ford settlement but class members had to seek reimbursement by march 16, 2006. since my 1997 ford crown victoria has only recently started leaking coolant, i guess i will have to fork over the repair monies myself. is there any chance of ford repairing this manufacturing defect gratis? f | |||
| 06/01/2007 | 100000 | 1 | 02/01/2007 |
| Tl*the contact owns a 1997 ford crown victoria. while driving 50 mph, the contact noticed smoke coming from the vents. she pulled over and exited the vehicle before it caught fire. the vehicle did not have insurance and was taken to the junk yard. the current and failure mileages were 100,000. | |||
| 05/12/2000 | 1 | ||
| 97 ford crown victoria and 97 mercury grand marquis with 4.6 v8 engines have both had the plastic intake manifold replaced due to cracking and leaking coolant and resulting in considerable expense. this owner joined a class-action suit held in federal court in oakland calif. and on 12-16-05 issued a judgment ruling that ford would reimburse for this problem. a very short three month period was provided for owners to claim this reimbursement. it is not known if the court required notification of the owners of this ruling. if it did this owner did not receive notification. the expense for both cars was $1500. ford notified fleet owners and offered replacement of the manifold. however, private owners were excluded. in view of this notification and the court ruling, reimbursement of this expense should apply to private owners. *jb | |||
| 07/09/2006 | 84000 | 1 | 06/15/1997 |
| The manifold cracked, engine overheated,blew heater core had to tow car miles for replacement. parts included manifold,gaskets, heater core and hoses. this at 84000 miles and no warranty. *jb | |||
| 06/12/2006 | 93600 | 1 | 08/20/2005 |
| 1997 crown victoria technical bulletin 05n04 nhtsa 10018959 date of bulletin: dec, 14, 2005 /incident june 12, 2006 this settlement extended the coverage of all composite intake manifold 7 years from the original warranty....where does that leave 1997 owners? the bulletin was released a year after the extended warranty coverage ended!? one year late for 1997 owners. what should we do because it is past the extended warranty? a defect is a defect with or without a time limit. we did not choose to have it break when it did....the defective part did that for us! what can we do to get this part/service covered? thank you for your time! *jb | |||
| 02/27/2006 | 84242 | 1 | 10/02/2003 |
| I was referred by mr. michael j. sacks at msacks@lemonlaw.com his response: it sounds like you are getting the run around and i would recommend you contact nhtsa in washington dc if the company is not willing to follow through with recalls. website is www.nhtsa.gov problem details: recently i received an estimate for work for $899.14 to fix a cracked manifold along with gaskets, and seals on my 1997 ford crown victoria, that i purchased from a used car dealership in baltimore, md in 2003. this piece was originally recalled by ford company, but never replaced by it's original owner, nor the dealership that i purchased the vehicle from. when this breakdown occurred i contacted the company where i purchased my extended warranty from in september of 2005. the claim was denied because they do not cover items that were recalled. i was then directed by the warranty company to call ford company directly, i followed up and made the call to find that the manifold that was recalled had a seven year warranty from ford company that had expired. i am now stuck with an $899.14 bill out of pocket expense for something i knew nothing about until it occurred. i feel that before selling me the vehicle this should have been investigated and taken care of by the dealership bruns motors. i am yet to be able to repair this problem, because i do not have the funds. please advise me in anyway that you can, your help is greatly appreciated. if i am not able to answer the phone please don't hesitate to leave a message. thank you for your attention to this matter. *jb | |||
| 01/30/2006 | 72600 | 1 | 02/10/1997 |
| Dt*: the contact stated while driving 2 mph slowing to a stop, steam was noticed coming from the vehicle. the vehicle was taken to the dealership for inspection. upon inspection, the dealership determined the intake manifold was leaking and the intake manifold, thermostat, water pump and hoses needed to be replaced. the manufacturer was notified however, no repairs were made. | |||
| 06/12/2005 | 78685 | 1 | |
| Dt: the vehicle is a 1997 ford crown victoria. on 6-12-05 the consumer was driving on route i40 when he smelled an odor coming from the vehicle. he called the highway patrol which arranged to have him towed to barstow. the vehicle broke down because the plastic intake manifold cracked. the vehicle lost all the coolant which caused the engine to overheat. when the mechanic from castners auto service 214 south bradford avenue, placentia, ca 92870 telephone # 714-528-1311 was removing the spark plugs he noticed that there was aluminum flaking on them. there was no compression. he replaced the engine and all the parts that went with it on 6-15-05 through 6-30-05. mechanic told the consumer that it would cost more to repair the engine than to buy a new one. the replaced engine was ford manufactured. consumer has not contacted the manufacturer as of now. vehicle was manufactured in october 1996. *ak *nm | |||
| 08/01/2004 | 67000 | ||
| I was driving down the highway when suddenly the passenger compartment began to fill with a white smoke and smoke came from under the hood of my car. i was able to get off the road and let the car cool off. i had the vehicle repaired at a ford dealership to the cost of $1100 for a cracked intake manifold which i was told was a common problem that ford was aware of and would only pay for the repair if my car was a taxi cab or a police car!!!!! *nm | |||
| 02/19/2005 | 37400 | 1 | 01/15/2005 |
| Cracked intake manifold discovered when car began to overheat, thermostat was replaced thinking it was a bad seal, only to discover the manifold was cracked. new manifold is on order $285 dollars, still waiting on the repair bill. *jb | |||
| 08/01/2004 | 86000 | 1 | 02/01/1998 |
| The composite intake manifolds developed fatigue cracks, resulting in total engine coolant leakage. complete loss of coolant resulted in engine failure, owner was lucky to be on local street and near to a car repair shop, spent $1100 on repair. *jb | |||
| 09/13/2004 | 69500 | 1 | 10/03/1997 |
| I was driving along the highway and my car started to overheat very quickly, within 2 minutes. the temperature got so hot smoke poured out, and the car staled. after a couple of minutes it cooled down enough to get it home, and then to the repair shop. smoke was everywhere. the repair person sighted that the intake manifold assembly was responsible, and that he has seen a lot of such problems in crown victoria's of the same year 1997. the repair was $989.54, and the milage on the vehicle is considerably low for the year. it only has 69, 500 miles. the repair shop has the defective manifold.*ak | |||
| 08/25/2003 | 84490 | 1 | |
| While driving 60 mph the temperature gauge went into the red and the vehicle began to overheat. the consumer was forced to pull to the side of the road. the vehicle was towed to the dealer where the technician diagnosed the problem was a cracked manifold and block. *ak *nlm | |||
| 06/10/2003 | 1 | ||
| Coolant sprayed out of engine which created stream to come from hood. consumer pulled to the side and allowed vehicle to cool down, and sit over night. he then had vehicle towed to a mechanic, who told him that his intake manifold was blown, and that he would have to replace it.*ak | |||
| ENGINE AND ENGINE COOLING - COOLING SYSTEM | |||
| 09/27/2008 | 67660 | 1 | |
| Intake plastic manifold cracked causing loss of coolant. vehicle had 67660 miles on it. this is the second crown vic we have owned and it will be the last. the first one's transmission went out just after the warranty ran out. we had to buy a second crown vic due to the steering modifications necessary for my wife to drive and the crown vic is the only car at the time that could be modified to the necessary standards. *tr | |||
| 05/04/2003 | 51691 | 1 | 09/17/1997 |
| Plastic intake manifold failed causing engine coolant loss and engine overheating. repair bill was $721.55. replacement manifold is a re-designed, two component palstic intake manifold/metal cross-over coolant tube. contacted ford for reimbursement but ford refused. wrote numerous letters and emails to ford but ford refused to take responsibility for the faulty engineering. i still have the defective manifold and continue to drive this sorry excuse of ford quality. what a joke. | |||
| 03/21/2005 | 115900 | 1 | |
| Car was running normally when i gradually started to smell coolant coming from under the hood. i looked and saw coolant leaking from around the thermostat housing. i went and replaced the gasket for the thermostat and added silicone. the coolant than started to leak even worse. i looked at the manifold and it appeared that there was a small crack on the housing. i found out that via the internet and a public works tech that the plastic manifolds were defective. i called a ford dealership and they said that it was out of their 7 year warranty. they said that i would have to pay for it. a kit costs around $589 and chevron quoted parts and labor at $1,050.*ak | |||
| 04/16/2003 | 07/10/1997 | ||
| Sole owner 1997 ford crown vic lx; intake manifold failed - april 16, 2003; tsb report issued by ford motor company; cost incurred - $1170.00. *nm | |||
| 11/17/2004 | 0 | 0 | |
| I was heading home from the grocery store when i got three to four miles of my home when i noticed from my rearview mirror, that there was a heavy mist billowing from behind my car. then i began to smell the coolant fluid soon after. i managed to pull into the next closest grocery to investigate. heavy stem from the coolant billowed up from the middle of my engine which soaked wires and other electrical instruments. i let it cool down for some time before i could add more water and set for home which was only less than a mile away. the next day i got the car to a mechanic so he could investigate to what the problem was. it was the intake manufold which was made of all things...plastic!!! the mechanic contacted and picked up the replacement that was made of metal. he had discovered that he was told that ford co. never sent out recall notices to crown victoria owners about the maifolds cracking. i had to pay over $500 for the part. along with parts and labor costs adding up to over $800. i am apsolutely buggered to put it nicely that they never said anything!!! knowing that there was a problem with the part! they just lost a steady ford customer not just because of my plight, but because other people were left in the dark about this serious problem! and yes! i have the old manifold and photos! *ak | |||
| 08/10/2004 | 76952 | 1 | 04/15/1998 |
| While driving the consumer noticed steam coming from the front of the hood. the vehicle was taken to the dealer for inspection. the mechanic informed the consumer that the intake manifold was crack and needed to be replaced. *jb | |||
| 04/17/2003 | 82035 | 1 | 04/19/2003 |
| Composite intake manifold developed fatigue cracks at the coolant crossover duct which created a loss of engine coolant ,heating the engine and cracking the heads. ford knows about this problem(ford tech bulletin dated 02/02/02 & special service message #10379) ford admits to faulty component and has made repairs to taxi`s & police vehicles ,but will do nothing for an individual with the same engine! *nlm | |||
| 07/28/2002 | 70422 | 1 | 10/20/1997 |
| While driving at 70 miles per hour the engine overheated. steam was coming from the radiator area and the fluid had boiled over. the vehicle was towed to the nearest ford dealership for repair. the cause was a cracked intake manifold and the whole engin needed to be replaced. the replacement manifold has been reinforced at the point of failure. i understand ford recalled police and taxis manufactured in this period but did not notify private owners of a possible defect. | |||
| 10/21/2002 | 1 | 08/01/2097 | |
| Driving on higway at 65 mph began to smell a burning odor, after pulling over to a safe location smoke came from under hood. when hood was opened for inspection it emitted a noxious odor and it was spraying hot engine coolant from the top of the engine. after engine cooled down coolant was added and car was driven a short distance home. vehicle was towed into the dealer expecting the repair to be covered by warranty either by the recall that is out (apparently currently only applies to police and taxis) or as listed in the owners manual for california emissions components defects. the dealer said this was not covered either way. a call to ford customer relations (edith) initiated a claim. edith said she would contact the dealer for assistance but my vehicle was not recalled. the dealer representative was recontacted and refused to offer any assistance whatsover. this issue is well established as nhtsa has the bulletins listed and there a numerous complaints documented. some people could drive their vehicle unknowingly with this defect which could result in fire or burning from escaping steam. ford motor company must reimburse me and others who have had expenses to repair their problem of a poor original design. the new part has been updated with an aluminum coolant crossover instead of plastic. dt | |||
| 09/05/2002 | 1 | 07/01/2097 | |
| The plastic coolant crossover on the intake manifold ruptured causing my wife to make an emergency stop on the side of the highway. my mechanic told me that ford was having a lot of these to fail. the new manifold is made with metal on the water crossover, the instructions with the new manifold even told the mechanics where to look for a coolant leak. this was a very expensive repair that i believe ford motor company should cover at least partly under a recall. nlm | |||
| 04/28/2002 | 1 | ||
| Ford motor company is aware that a crack is likely in the plastic front coolant crossover on the intake manifold assembly (4.6l engines). this is listed as a ford technical service bulletin dated 02-02-02 and as a ford special service message #10379. when the crack occurred on my vehicle, it stranded my wife and i in the florida everglades on a hot sunday afternoon. total costs incurred were over $1,000 of which maroone ford charged me $773.75 to replace the intake manifold. the replacement crossover is made of metal, not plastic. not only was this a financial liability, it is a safety hazard. anyone who inspects the engine compartment at the time of initial trouble shooting will become severely burned by hot coolant boiling out of the crack of the plastic crossover. | |||
| 04/28/2002 | 1 | ||
| Ford motor company is aware that a crack is likely in the plastic front coolant crossover on the intake manifold assembly (4.6l engines). this is listed as a ford technical service bulletin dated 02-02-02 and as a ford special service message #10379. when the crack occurred on my vehicle, it stranded my wife and i in the florida everglades on a hot sunday afternoon. total costs incurred were over $1,000 of which maroone ford charged me $773.75 to replace the intake manifold. the replacement crossover is made of metal, not plastic. not only was this a financial liability, it is a safety hazard. anyone who inspects the engine compartment at the time of initial trouble shooting will become severely burned by hot coolant boiling out of the crack of the plastic crossover.*jb | |||
| 12/29/2001 | 1 | ||
| Engine has never overheated. cooling system very clean. spontaneous crack developed in plastic intake manifold croosover tube, directly behind alternator. immediate coolant loss through 3.5 crack. replacement part looks identical, no visible improvement. ford admits to faulty component through service bulletins,and has made repairs to fleet vehicles. dealer states they will do nothing for individual owners.*ak | |||
| 10/11/2001 | 1 | 09/01/2000 | |
| This is a known ford issue, yet they deny responsibility. no safety defect listed. *ak | |||
| 09/04/2001 | 1 | 01/01/1999 | |
| Intake manifold is leaking radiator fluid. my mechanic said a recall was issued for this exact problem, but ford refused responsibility. 10 complains(same) listed on defective investigation for same car and date.*ak | |||
| 07/01/2000 | 1 | 01/01/1997 | |
| No summary listed for above vehicle. *ak | |||
| 06/01/2000 | 1 | 05/01/1997 | |
| No summary | |||
| ENGINE AND ENGINE COOLING - COOLING SYSTEM - HOSE | |||
| 01/30/2006 | 72600 | 1 | 02/10/1997 |
| Dt*: the contact stated while driving 2 mph slowing to a stop, steam was noticed coming from the vehicle. the vehicle was taken to the dealership for inspection. upon inspection, the dealership determined the intake manifold was leaking and the intake manifold, thermostat, water pump and hoses needed to be replaced. the manufacturer was notified however, no repairs were made. | |||
| ENGINE AND ENGINE COOLING - ENGINE | |||
| 12/04/2009 | 60140 | 1 | |
| I was driving home from work and thought a coolant hose had ruptured but after having the vehicle towed to my mechanic's place of business was told that the intake manifold had cracked and required replacement. after researching i found that ford had issued a recall for only a few models even though most of their 8 cylinder 4.6 engines utilized the same defective composite intake manifold. my crown victoria is a 1997 with 60,000 original miles! *tr | |||
| 06/12/2007 | 1 | 01/01/2007 | |
| Tl*the contact's son owns a 1997 ford crown victoria. the vehicle caught on fire under the hood while parked. the owner of the vehicle noticed smoke filling up inside of the vehicle, then lifted the hood and flames began to rise. the wires to the master cylinder and brakes were damaged. the contact notified ford and they stated that there were no recalls for the vehicle and that it was out of warranty. however, there were recalls for trucks of that line. the vehicle is currently at the ford dealer. the power train and mileage information were unknown. | |||
| 04/28/2006 | 187000 | 1 | |
| The class action suit that was won regarding 1997 ford crown vic (and other makes) defective manifold part was handled incorrectly. mine just went and is well past the march 16th, 2006 deadline and over 7 years old which makes recourse exempt. my car is currently in the shop getting a $1300 + engine repair. and i am not the only one that this has happened to. definitely not fair!!! *jb | |||
| 01/16/2006 | 67000 | 1 | 10/01/2005 |
| I bought a used 1997 crown vic in 2005 and i noticed coolant leakage on jan 16, 2005. the leakage might have happened before i bought the car, but it was not obvious enough for people to notice the problem. *jb | |||
| 03/22/2005 | 55900 | 2 | 11/29/2003 |
| The following is a well known and well documented design crown victoria 4.6 engine failure, which ford has ignored and claimed it is investigating for the ordinary consumer, while providing extended warranties for police cars and taxis. obviously, they don't want to lose this fleet market. there have even been news stories on this via nbc. the failure relates to a plastic intake manifold cracking prematurely, causing complete loss of coolant fluids, extreme consequent engine overheating, and resultant catastrophic engine failure. they sell the replacement and re-engineered part for nearly 600 dollars and charge almost 500 dollars additional to install it. this is a non-moving part which should not fail under normal use! there is even an entire aftermarket business making these parts as a replacement for less money...although i suspect most folks just pay ford to do the repair. queries to dealers meet with a reiteration of the above information and a kind sorry, it's not covered reply. i believe this is a case of fraud and misrepresentation of fitness, as opposed to the normal risks of wear and tear...their policy regarding lucrative fleet extended repairs speaks to this, in my opinion. this is a safety hazard defect due to engine stalling and power assist loss.*ak | |||
| 04/16/2004 | 3 | ||
| Cracked intake manifold. *jb | |||
| 01/03/2004 | 86000 | 1 | 10/13/2002 |
| While driving, the plastic intake manifold cracked. this caused coolant to leak from the intake manifold. *ak the factory intake manifold included the thermostat housing as one piece. the crack developed at the thermostat housing which required the entire manifold to be replaced. *jb | |||
| 09/27/2003 | 99430 | 1 | 08/04/1997 |
| My 1997 ford crown victoria blewout a kit intake manifold on the interstate and i had to have it towed to coastal ford for repairs in mobile alabama after looking on the internet i find that this was not a uncommon fault of the automobile. also a friend of mine had a 1997 ford thunderbird that had the same type problem and it was covered under a recall. after emailing ford i was informed by dereck #2132 at ford customer relations that my car was not covered but to keep the receipt in case of a recall. *jb | |||
| 02/14/2003 | 77450 | 1 | 10/30/1997 |
| This is a complaint about my 4.6 v-8 crown vic. the intake manifold cracked resulting in a loss of coolant and a 750.00 repair bill. the manifold is made of a composite not metal.so this could happen again. sounds like a design flaw. also, why is ford replacing the police and municipal cars manifolds and not private citizens?? this information came straight from the mechanic at the ford dealership. | |||
| 12/29/1997 | 1 | 05/12/1997 | |
| Body mounts are collapsing causing under carriage to rub flat spots on steel brake lines. | |||
| ENGINE AND ENGINE COOLING - ENGINE - GASOLINE | |||
| 04/11/2004 | 100000 | 1 | |
| Catastophic cooling failure. intake manifold replaced for $900. mechanic noted that this was common on ford crown vics with defective plastic intake manifolds (they now use metal). understand this has been recalled in crown vic taxis and police cars, but not in other crown vics. why not? won't buy a ford again. ford owes me for the cost of the failure of this defective part.*ak | |||
| 09/15/2002 | |||
| While driving vehicle caught on fire from plastic manifold, and engine shut down.. dealer has been notified. any additional information feel free to add. *ak | |||
| 09/18/2000 | 5 | ||
| Vehicle experiences stalling at slow speeds in traffic and at stop signs, dealer has replaced idle air control and fuel pump and has reprogrammed the computer, however the stalling still occurs and the dealer can not remedy, consumer has almost been rear ended on two occasions, when stalling occurs, all power steering is lost, possibly engine or computer related. *slc | |||
| 1 | |||
| Engine fire. | |||
| ENGINE AND ENGINE COOLING - ENGINE - GASOLINE - BELTS AND ASSOCIATED PULLEYS | |||
| 06/20/2002 | 1 | 02/01/2000 | |
| Faint sudden noise from the engine compartment (coolant causing serpentine belt slippage, i believe) and then the engine overheated. due to roughly a 3 inch crack in the intake manifold plastic composite which dumped coolant into the back of the alternator. i was able to pull off before the engine was damaged. both the dealer, who is to be commended for a quick and effective repair (makes one wonder if the mechanics have had a lot pf practice with this repair), and ford motor company tell me there is no relief for repairs on a car with my vin although the replacement part is constructed of metal and composite rather than composite alone. i appreciate this design change which hopefully will ward off another similar failure but doesn't changing the design recognize that there was a weakness? on this same web-site i read that some ford fleet vehicles were recalled and repaired. concerning safety, the only issue this senior citizen faced was the stress of walking four tenths of a mile in the june heat and humidity to call for help and in paying the tow and repair expense. one is not surprised or greatly upset when the alternator wears out - but the intake manifold? what kind of stress testing did this non-moving part get when approved for production?*ak | |||
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL | |||
| 01/21/2001 | |||
| Engine check light on and run rough due to maf sensor failure. the hood would pop up while driving due to hood latch malfunctioning.*yh | |||
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - MANIFOLD/HEADER/MUFFLER/TAIL PIPE | |||
| 05/10/2008 | 100000 | 1 | 06/03/2003 |
| Tl*the contact owns a 1997 ford crown victoria. while driving approximately 55 mph, the contact felt a strong gust of heat coming through her vents. she pulled over to the side of the road and had the vehicle towed back to her residence. the vehicle was unable to be driven. a local mechanic came to service the vehicle and informed her that the plastic intake manifold cracked and needed to be replaced with an iron intake manifold. the vehicle was repaired at the contact's expense. the manufacturer has not yet been notified. the failure and current mileages were 100,000. updated 06/17/08. *lj | |||
| 08/30/2007 | 8590 | 1 | |
| Intake manifold on my 1997 ford crown victoria cracked allowing coolant to leak into manifold. there was a class action suit in 2005 which i never was told about. *tr | |||
| 08/10/2007 | 93608 | 1 | 04/06/2002 |
| I own a !997 crown victoria, which overheated due to a crack in the intake manifold. i have owned this vehicle since 4-06-2002, and did not know about the recall until i looked it up on the internet! i had to pay for the repair myself, i think i should have been notified by ford! *jb | |||
| 05/25/2007 | 81991 | 1 | 11/15/1996 |
| 1997 ford crown vic traveling east of austin tx at posted highway speed when a crack developed in the intake manifold with resulted in loss of coolant , and subsequently motor function. towed to authorized lincoln mercury dealer in austin, and was informed by tow truck driver that this was very common defect for this model car , and suggested i contact ford people for a recall notice. was advised by the ford representative at the 800 telephone number provided in the owners manuel that no recall was in effect however, no cost repair was available to those vehicle seven years or under. a further program through the dealers may also be available named customer satisfaction programmability this had restriction of eight years and 80000 miles. my car didn't qualified for either program due to age and mileage even though the car has meticulous being taken care of and was under 82000 miles. upon completion of a new intake manifold installation at a cost of $1029.98 dollars it was determined the engine was a total loss as the engine must have been damaged due to loss of coolant and resultant overheating. a replacement motor was quoted at $6000 dollars on top of the already incurred $1029.98 dollar expence. the car was junk!!! i find it difficult to understand why no recall was in effect since ford knew there was a problem. the mechanic told me they had many similar repairs in their shop. also informed all similar police models were repaired without restrictions. if this is so i can't understand why i am discriminated. i would like the ford corporation reimburse my expenses and/or give me a voucher for a substanial discount on a new ford vehicle. *ak | |||
| 10/01/2006 | 89000 | 1 | |
| Tl* - the contact stated that the intake manifold cracked and leaked coolant. the vehicle has approximately 89,000. the contact was driving 55-60 mph on the interstate, and the weather conditions were fair. the contact saw a plume of white smoke following behind him. the contact immediately drove the vehicle to a repair shop. there were no warning signs or signs of overheating. the dealer removed and replaced the intake manifold and added engine coolant. *ak updated 01/26/07. *jb | |||
| 12/19/2006 | 87419 | 1 | |
| Tl* - the contact states that there was a recall on his 1997 crown victoria. the contact said that 8:20 am on 12/19/06 while attempting to pass another vehicle when he notice a large trail of steam and smoke coming from the rear of his vehicle. the contact pulled to side of road and steam and smoke stopped, at which time he opened hood of vehicle and noticed coolant running on top of the engine. contact called the ford dealership of kansas. the ford dealership informed contact that the intake radiator had cracked. the representative then asked questions regarding the problem and told him that there was a recall on the intake fuel manifold but, that the recall had expired in 2004. the representative also told the contact that the intake had to have a crack in it in order for them to have repairs done. | |||
| 07/09/2006 | 84000 | 1 | 06/15/1997 |
| The manifold cracked, engine overheated,blew heater core had to tow car miles for replacement. parts included manifold,gaskets, heater core and hoses. this at 84000 miles and no warranty. *jb | |||
| 05/28/2004 | 110482 | 1 | |
| Dt*: the contact stated while driving the vehicle the heat hand started to rise. the contact drove the vehicle to an independent repair shop. upon inspection there was water leaking from under the vehicle. the mechanic found the problem to be the intake manifold was broken. repairs have been made. the manufacturer has not been alerted. updated 03/22/06. *jb | |||
| 01/30/2006 | 72600 | 1 | 02/10/1997 |
| Dt*: the contact stated while driving 2 mph slowing to a stop, steam was noticed coming from the vehicle. the vehicle was taken to the dealership for inspection. upon inspection, the dealership determined the intake manifold was leaking and the intake manifold, thermostat, water pump and hoses needed to be replaced. the manufacturer was notified however, no repairs were made. | |||
| 08/06/2005 | 77000 | 1 | 04/16/2003 |
| I own a 1997 ford crown victoria and while driving on expressway the car overheated and i immediately pulled of the road. after towing to mechanic he immediately diagnosed the problem as a very common one. that being the plastic engine manifold that has been a part of a fully covered warranty/recall item if your vehicle was a police or fleet vehicle. the fact that it is not covered to the private car owner does not make sense. who would think such a important component make of plastic would be acceptable to any car owner. *nm | |||
| 04/05/2004 | 61705 | 1 | 08/09/1997 |
| 1997 ford crown victoria w/61,705 miles was making a strange sound. thinking it might be the brakes, i took it to a service center. while they were testing it smoke started poured out of the hood. the result indicated there was a crack in the plastic' manifold which had to be replaced w/a ford part that was a metal part. i understood there was a recall that only included police or fleet cars. it seemed to me that there should be some recourse toward the ford motor company. this car had only 61,705 miles on it. who would think a plastic manifold would hold up at all? not me certainly. *ak | |||
| 03/21/2005 | 1 | ||
| The intake manifold is made of plastic. it splits at the casing seams, which causes anti-freeze to shoot all over the engine.*ak | |||
| 11/15/2002 | 91021 | 1 | |
| Intake manifold cracked causing plug sockets to fill with water causing vehicle to stall. *nm | |||
| 04/26/2004 | 43984 | 1 | 07/29/1997 |
| (1) we were driving on the freeway and my car sounded like something exploded and it got so hot and lost all of the fluids in the car. (2). we had to get it off the freeway and have it towed into mccoy mills ford. the intake manifold, was made of plastic and it cracked and the car was burning hot. it could have very easily caused and accident. defect in the intake manifold. it was replaced , total expense - $1028.54. they would not replace it free, but i feel ford should have to refund me for fixing it, since it was a defect and made from plastic. i didn't think to ask for old parts. the service man told me it was made of plastic and that they were using metal now. i also found out that a lot of the police cars, the crown victoria's, have done the very same thing. i would like to know if a lawsuit has been started against ford, if so, i would like to join it. *ak | |||
| 06/30/2003 | 1 | ||
| Safety defect with intake manifold.*mr the intake manifold on certain passenger vehicles manufactured by the ford motor company has failed. once this failure occurs the intake manifold may cause the engine to seize and fail and may cause an accident. when notifying ford they refused to reimburse the consumer for repairs on defective parts. please respond promptly in resolving matters. *cb *jb | |||
| 05/02/2004 | 88565 | 1 | 04/13/1998 |
| We were traveling on i-15 in a remote area of utah. when our car's intake manifold ruptured but didn't know it at the time and lost all of the coolant -stranding us. the failure of the manifold led us to be towed to beaver and then from beaver to st. george utah. we learned the ford motor company knew there was a problem with this particular engine 4.6 liter and it happen quite frequently. they were replacing the defective manifold on an as needed basis. we left the car to be repaired at the st. george ford dealership and had to rent another car. st george ford told me that they would put on a new manifold which was not all plastic, but that they would not help me off set the cost of replacement. st. george ford said because i had more then 75,000 miles on the car, that they wouldn't help with the expense of the $1093.00 repair plus $ 347.00 towing fee. i think a part that is this defective should be a voluntary replacement by the ford company for the life of the car. this is an all plastic part they knew it was defective because they have retooled and made a cast metal replacement. i think that when this happens it is an unsafe situation and it also leaves you stranded on the freeway or back country where we live. ford also told me they were replacing the manifold on an as needed basis on police cars and other vehicles with the 4.6 liter engine for unlimited mileage. *ak | |||
| 04/10/2004 | 66000 | 1 | |
| While driving steam came from under the hood, and the temperature gauge read hot. this occurred because the intake manifold cracked and anti freeze leaked out. dealership replaced the cracked intake manifold with a new redesigned intake manifold.*ak | |||
| 1 | |||
| While driving consumer noticed an unknown aroma inside the vehicle. consumer had vehicle inspected, and a technician determined intake manifold as the cause. *ak | |||
| 02/08/2004 | 99000 | 1 | 01/05/1998 |
| 1997 crown victoria lx - 4.6 l engine with 99,000 miles. my manifold intake cracked and failed, resulting in rapid and complete loss of engine coolant. required towing. repair estimated to cost $1,100. ford has been aware of this issue since 1996 and has recalled 1996-2001 crown victoria taxis, limos, and police cruisers for this very same problem, but did not recall private vehicles with the same faulty part. ford did not even notify owners of this defect. i request an investigation be made into the reason why private vehicles were excluded from this recall, as there can be no technical reason. i would also request that ford be compelled to pay for repairs made to cars previously repaired.*ak | |||
| 05/07/2003 | 1 | 02/07/1998 | |
| Defective intake manifold caused coolant to leak . *ak | |||
| 09/22/2003 | 139000 | 1 | 10/19/1996 |
| Intake manifold cracked. *ak *mr | |||
| 12/28/2003 | 65000 | 1 | |
| While driving intake manifold assembly exploded, causing the vehicle to stall. manifold assembly was replaced by an independent mechanic. *ak | |||
| 11/30/2003 | 47000 | 1 | 03/11/2000 |
| The manifold in my 1997 crown victoria cracked. i understand that this is a defect particular to the 4.6 liter engine which my car has. my car is low mileage (about 47,000) is six years old and i am the second owner having had it for 4 years. i have had regular service by the dealer from whom the car was purchased. i understand that the manifold on this particular size engine has been found defective in other model cars and although a recall was issued my vin no. does not match a specific list and therefore, i have to cover the $1000 expense. i will not buy another ford when i sell the one i now own and i will strongly encourage others not to buy any model car with this engine. i plan to file a small claims lawsuit against ford when i have all the repairs completed. fortunately, i had only driven a mile from home and my husband was with me when this occurred. had it not been for his attention to details things would likely have been really bad.*ak | |||
| 08/24/2003 | 45 | 1 | 07/11/1997 |
| Plastic intake manifold cracked 8 below alternator.*jb | |||
| 08/12/2003 | 45690 | 1 | 05/10/1997 |
| Plastic intake manifold on 4.6l cracked. r&r cost $1000.00. part was $500+.*ak | |||
| 05/25/2003 | 1 | ||
| Consumer states that the plastic intake manifold is split.*ak | |||
| 06/19/2003 | 1 | ||
| Intake manifold has cracked, he had it towed , checked out, and repaired. it cost him $600.00 plus. consumer thinks thatthat this sould be a recall because it should not have happened.*ak | |||
| 06/11/2003 | 125000 | 1 | 10/04/2001 |
| While driving my 1997 ford crown victoria down the highway there was a gush of smoke behind my car and it started to over heat. stopped and found anti freeze spraying out of exhaust manifold. had it towed to a mechanic that advised me that ford had updated plastic manifold part with an aluminum part but did not do a recall. $1,000 dollars later i was back on the road. we are ford people and very disappointed in ford for not recalling this item. i had my whole family with me and 3 hours from home, had to pay for another night of lodging and food on top of the whole experience being stressful i am out $1,000 dollars. we are going to write to ford and better business bureau. after that we will go to small claims court. *nlm | |||
| 90000 | 1 | ||
| Intake manifold had cracked and anti-freeze has leaking out. *ak | |||
| 06/10/2003 | 1 | ||
| Coolant sprayed out of engine which created stream to come from hood. consumer pulled to the side and allowed vehicle to cool down, and sit over night. he then had vehicle towed to a mechanic, who told him that his intake manifold was blown, and that he would have to replace it.*ak | |||
| 05/08/2003 | 40960 | 1 | 01/02/1997 |
| 1997 4.6 v-8 crown victoria plastic intake manifold... cracked while driving on highway resulting in coolant loss and repair cost of $779.repair was made by ford dealer quoting a service bulletin # tsb-02-02-02.*ak internet inquires show widespread failures of these manifolds in ford and mercury engines, with a supposedly extended warranty for the repair however only law enforcement and cab fleets are covered at no cost. individuals must pay for repairs, towing, rental cars, etc. | |||
| 06/26/2002 | 105000 | 1 | 02/18/1997 |
| While in motion, there was an explosion under the hood. the intake manifold had blew out. the mechanic who worked on the vehicle, showed consumer a recall notice for the exact incident. consumer is requesting a refund minus the labor. *jg *jb | |||
| 10/29/2002 | |||
| Consumer was told the intake manifold in the vehicle is made of plastic. consujmer states' manifold cracks causing vehicle to overheat and destroy engine. consumer has to replace the engine. please provide any furthert information. | |||
| 06/16/2002 | |||
| Loss of coolant is due to a cracked engine manifold. manufacturer was notified. feel free to provide any further information.*ak | |||
| 03/01/2002 | 1 | ||
| Coolant was leaking from vehicle. dealer determined that intake manifold was cracked. there was a recall 01f02500on for this part, but only police cruisers and taxi vehicles were affected.*ak dealer replaced cracked intake manifold, also the fuel filter was replaced. *tt | |||
| 06/18/2001 | 1 | 01/31/2000 | |
| Engine manifold developed a crack and started to spit out anti-freeze and water. consumer stated that dealer replaced engine intake manifold. *ak consumer was told there was a recall on some models, however his was not included, consumer is requesting reimbursement. front brake rotors and front brake pads replaced. *slc | |||
| 07/27/1998 | 1 | 02/11/1998 | |
| Intake manifold failed prior to recall. | |||