Bulletins


BulletinBulletin dateReplacement BulletinItem no.SummaryAdded
ENGINE AND ENGINE COOLING
022202/04/2002630628Some vehicles may exhibit an intake manifold crossover (first runner) coolant seepage condition. *tt04/19/2002
99B2912/01/1999612219Some vehicles may experience engine coolant leaks at the engine front cover gasket. owner notification program providing replacement of the engine front cover gasket. *tt06/07/2000
1318609/01/19996090542Information regarding front cover & water pump bolts-torque valve revision/3.8-4.2l. *mjs03/21/2000
9920710/04/19996089651Subject on engine coolant leaking into the engine oil on some vehicles. *tt02/11/2000
9913106/28/1999606484Concerns with engine coolant leaking into engine oil on some vehicles. *tt08/25/1999
9705011061705/01/199752896Vehicles may experience illumination of the engine cooling indicator light. *tw10/30/1997
ENGINE AND ENGINE COOLING - COOLING SYSTEM
BC019297020101/02/199751063Low coolant light stays on. the low fluids module in the cluster not making electrical contact wth the flex curcuit in the cluster. *jd06/27/1997
ENGINE AND ENGINE COOLING - COOLING SYSTEM - HOSE
BC324397021002/10/199751865Engine cooling light on - possible oil leak at upper jam nut on the upper transmission cooler line. *tw07/17/1997
ENGINE AND ENGINE COOLING - ENGINE
0721210/01/200710023943Some 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. *pe02/20/2008
0222111/11/200210008304Engine-gear driven synchronizers-incorrect installation-camshaft position synchronizer (cmp) installation tool correct application. *mj07/27/2004
87019710/22/200210000592Incorrectly installed gear driven camshaft position (cmp) sensor synchronizer assemblies causing surge, lost of power, malfunction indicator lamp on and diagnostic trouble codes p1336, p1309 and p0340. *tt03/25/2003
99B29#104/01/200099B29613562Information regarding replacment of engine front cover gasket. **mr07/21/2000
1318009/01/19996090538Information regarding camshaft position (cmp) sensor alignment tool chart. *mjs03/21/2000
699609/01/19996090309Information regarding a change in the torque values of the engine front cover water pump bolts. *tt03/14/2000
699709/01/19996090310Some service manuals may list the incorrect camshaft position sensor alignment tool for vehicles with various engine sizes. *tt03/14/2000
98322402/12/1998607436Some vehicles may have water contamination in the air filter and / or the mass air flow sensor. *tt09/23/1999
987404/13/1998601343A new silicone gasket and sealant. *yc07/24/1998
9761003/17/199751990Blower motor- chirping or squeaking from blower motor at low speeds. *jd07/17/1997
ENGINE AND ENGINE COOLING - ENGINE - GASOLINE
0124612/10/2001630515Engine oil system priming procedures, service tips for reports of premature engine failure. *tt04/18/2002
021401/21/2002630001Some engine assemblies with aluminum cylinder heads repaired in-vehile have been found to leak coolant and/or oil from the cylinder head gasket area. *tt04/11/2002
014703/05/2001619424Subject regarding engine oil recommendations for use in 2001 vehicles - sae 5w-20 motor oil. *tt05/30/2001
98310802/01/1998607402Effective march 2, 1998m3.8l engine assembly is added to fqr(ford quality renewal) assembly program. *ak12/21/2000
98310702/25/1998607401Brief information regarding engines being added to the fqr (ford quality renewal) assembly program. *tt09/22/1999
9981605/03/1999606420Ford motor company now recommends sae 5w-30 viscosity grade for servicing any ford gasoline-powered vehicle regardless of model year. *tt08/19/1999
ENGINE AND ENGINE COOLING - ENGINE - GASOLINE - BELTS AND ASSOCIATED PULLEYS
BC328897020602/06/199751884Vehicles may exhibit a cold start engine fead belt chirp noise. *tw07/17/1997
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM
98201010/12/1998603695Experiencing a buzzing or rattling noise from the exhaust system. *yc03/02/1999
986403/30/1998601312Information on a buzzing or rattle noise from the exhaust system. *tt07/21/1998
BC049096111211/12/199650763Instructions for replacing diagnosed failed component. *tw06/17/1997
BC040796111511/15/199650753Instructions for replacing diagnosed failed parts. *tw06/17/1997
BC971496110111/01/199650860Diagnostic instructions for servicing evaporative emission purge flow system. *tw06/17/1997
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL
98231011/23/1998603724Mass air flow (maf)- sensor contamination- service tip. *ak03/03/1999
983402/16/1998600588Air inlet-water in air inlet elbow-malfunction indicator lamp (mil) illuminates due to water contamination of air filter and/or mass air flow sensor (maf)- vehicle swith 4.6l engine. *ak05/27/1998
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - MANIFOLD/HEADER/MUFFLER/TAIL PIPE
05N0412/14/200510018959Extended 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 manif01/25/2006

Consumer Complaints


Fail datemilesoccurencesPurchase date
ENGINE AND ENGINE COOLING
05/01/20091
 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. *tr
02/27/20091590001
 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. *tr
06/12/2008345181
 Engine idle racing. can't stop unless placed in neutral, where car would run over 2000 rpm. dealer replaced idle air control and power control module. dealer stated that idle air control burns out the power train control modules on many v-6 ford engines. car had only 34,518 miles checked other surges that this is a safety issue of racing engines in accidents of v-6 motors and ford refusing any recalls for possible fire of idle air control and the burning out of power train control module. *tr
10/25/2002115000110/15/2002
 I purchased this 1997 ford thunderbird lx sport as a used vehicle in oct. 2002. i noticed that during the first few weeks of owning this vehicle it would intermittently leak a substantial amount of coolant onto my driveway but i could never see where it was coming from. sometimes it would go for days without leaking and then one day there would be over a quart of coolant on the driveway. i brought the car into a shop that put the car on a lift to look for the leak but they could not find one. i continued to drive the car and add coolant every time the low coolant light appeared on the dash panel. in may 2005 i was on the 91 freeway and suddenly without warning the low coolant light came on and the temp came up quickly so i tried to change lanes to the right to exit the freeway and the back of the car broke loose and i almost turned sideways. i found out later that the rear tires and wheel wells were soaked in coolant. this was the first time that i found out that my intermittent leak that no one could find was my intake manifold at the base of the thermostat housing. i went to rancho santa margarita ford and asked about recalls and they told me that the recall for the intake manifold had expired a couple of months ago and that there was nothing that they could do. i called ford motor co. customer relations and was told the same thing. the car now sits parked unrepaired. i cannot afford to pay almost two thousand dollars to correct fords engineering blunder. *jb
10/13/200526000108/12/1997
 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. *nm
05/01/2005980001
 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.*jb
08/30/2004654901
 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. *jb
07/31/200162365112/14/2000
 Engine manifold cracked allowing antifreeze to escape. took car for repair. learned later that repair was a recall. asked ford for reimbursement. reimbursment denied.*ak
09/15/200348000105/05/2003
 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. *jb
111/01/1997
 Heat indicator on dash board failed. yh
ENGINE AND ENGINE COOLING - COOLING SYSTEM
09/13/2007203500111/11/1997
 Plastic intake manifold failure. *jb
04/06/200672950109/01/2004
 Intake manifold split causing coolant leakage. *nm
05/26/2004120811110/27/2002
 Vehicle would not hold any radiator fluid,causing the temperature gauge to rise. tried to refill the radiator fluid, but 5 minutes later it ran out. could not drive vehicle. took the vehicle to my mechanic,who told me that the intake manifold was cracked and needed to be replaced. he replaced the intake manifold,so the i would be able to drive the vehicle.
12/12/200450090107/02/2004
 Engine front cover gasket failed in line with recall 99b29. ford does not include my car built 04/97 in recall campaign 99b29 indicating the original recall has been inadequate. *ak
02/03/200482275109/01/1997
 I had to replace the coolant inlet manifold on my 1997 ford thunderbird. this should have been covered by ford recall #97m91 but for some reason ford has excluded my vin no. from the recall. this problem was clearly caused by a defective part and was replaced with an upgraded part.*ak
08/01/200362000108/01/1997
 Fatigue crack in intake manifold of 4.6 l engine that that caused loose of coolant and the engine to over heat. my 1997 ford thunderbird is not part of the recall even thought it has the same engine and defective manifold. repair cost is $600.00. ford already has a recall and the follow was coped from source: ford motor company documents ford motor company will extend the recall (01m02) on 4.6l v8 equipped vehicles with plastic intake manifolds. some of the composite intake manifolds used on 4.6l sohc engines may develop fatigue cracks at the coolant crossover duct. this condition could result in engine coolant leakage which, if not serviced, may cause engine overheating. complete loss of coolant may result in engine damage or engine failure. the updated recall now includes: certain 1996 through 2001 model year crown victoria police interceptor certain 1998 through 2001 model year crown victoria with taxi certain 1998 through 2001 lincoln town car limousine and livery prep package certain 1996-2001 crown victoria taxis, police cars and lincoln town car limousine and livery cars. certain 1996 through 1997 crown victoria police interceptor vehicles with 4.6l sohc engines built at the st. thomas assembly plant from the beginning of production for the 1996 model year through january 28, 1997. certain 1998 through 2001 crown victoria police interceptor vehicles with 4.6l sohc engines built at the st. thomas assembly plant from november 22, 1997 through december 15, 2000. certain 1998 through 2001 crown victoria taxi vehicles with 4.6l sohc engines built at the st. thomas assembly plant from november 22, 1997 through december 15, 2000. certain 1998 through 2001 lincoln town car limousine prep package and livery vehicles with 4.6l sohc engines built at the wixom assembly plant from november 22, 1997 through december 15, 2000.
ENGINE AND ENGINE COOLING - COOLING SYSTEM - RADIATOR ASSEMBLY
01/12/2000103/01/1997
 They replaced the manifold and then the radiator malfunctioned, 18.000 miles later the heater core failed, was replaced in the last 6 months since aug 4 times. ford does not have a clue and the dealer is trying to fix it each time at leaks.the brakes/rotors have been a cronic problem since the car was new. the calipers have been resurfaced 3 times and finally replaced.*ak
11/01/199705/01/1997
 Radiator began leaking coolant. car run hot. previously engine manifold cracked. at that time(october 99), engine ran hot and smoke was coming from under hood. they replaced the manifold and then the radiator malfunctioned. the engine is now running harder and the noise level is higher. i fear that with the car overheating so many times permanent damage may have been done to the engine heads. the car is almost out of warranty and i fear i may get stuck with an engine repair job after the warranty expires. *ak
ENGINE AND ENGINE COOLING - ENGINE
07/03/201155770
 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?
01/01/19011
 1997 ford thunderbird motor died while driving.*mr ***not in repository. *nm
08/19/200467452108/31/2002
 Cracked intake on my 97 t bird. *jb
06/05/20031
 The plastic intake manifold cracked which caused coolant to leak and the vehicle over heated. *jb
01/11/2002107/01/1998
 Head gasket blew. engine ruined. vehicle lost power. smoke poured from engine. there was no fire. i saw no indication of problrm on panel. notificatio on panel lit up as vehicle slowed down to service engine. *ak
01/11/20021
 While driving approximately 65 to 70 mph, engine unexpectedly lost power and white smoke started coming from engine compartment. independent garage examined vehicle and diagnosed head gasket had failed, and was replaced. *ak consumer states because of all the other failures the engine was ruined and also needs to be replaced. *jb
12/12/2001310/31/1996
 Due to the location of cup holders spillage from cups get into gear shift. dealer has been notified. *ak the consumer stated that due to design and location of the cup holder any spill of liquids gets into the gear shift area causing the gear shift to get hard and also, hard to remove key from ignition when the transmission was in park. engine leaks oil due to rocker arm cover failure. *yh
01/03/2001
 Loss of coolant and white smoke;vehicle taken to an independent shop, and informed consumer of a of a head gasket failure. notified manufacturer, and informed consumer vehicle was not covered under a recall or extended warranty. please feel free to provide any further details on this matter. *ak
05/27/200001/01/1997
 3.8 liter v6 ford engine head gasket defect 1997. *ak
07/01/1998110/01/1998
 Rivets failed caused oil pan cover dropped. yh
ENGINE AND ENGINE COOLING - ENGINE - GASOLINE
12/01/1997
 Engine pinging and engine check lightconstantly reappears. source of problem is maf sensor. *ak
04/21/2000208/01/1997
 No summary listed for abov evehicle. *ak
11/01/19992
 No summary listed for above vehicle. *ak
09/26/1999105/01/1997
 While driving heavy smoke begin coming from under the hood. the car registered hot and started to make clicking sound. immediatedly cruise out of traffic. told i had a cracked manifold and all fluids had spilled on the engine. i am concerned sever damage had been done to the engine when all is being repaired is the manifold. in the future i do not want to have to pay foe a new engine when a defective manifold caused the problem.
109/05/1997
 Vehicle performing sluggishly. nlm
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM
01/06/2002109/01/1997
 The original warranty booklet that came with car when i purchased it stated that emission sensors would be covered under warranty for 7 years or 70,000 miles under california emissions which i have on my car...when catalytic sensor monitor failed ford refused to cover it under warranty, and i was forced to pay $269.to have repair done by dealership...ford motor company should be held accountable for not complying with safety and emision standards..*ak
02/28/2001502/01/2001
 I experience dizziness, nasea, and headaches after driving on the interstate 1-75 for approximately 10 minutes. i had to pull over to the side of the road and open all the windows. after 10 minutes my head cleared enough to drive to the next exit and get off. this is the fourth or fifth time this has happened. i am afraid now to drive my car with the windows up. *ak
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL
07/22/200533573107/15/1997
 To whom it may concern! my 1997 ford thunderbird is not listed why? i have a lot of problems with the smog stuff every year i pay a lot of money. when temperatures are hot outside over 90 the engine light comes on and says service engine, or when i go up a long hill and my car overheats the engine light comes on and says service engine and it is always about an oxygen sensor or other smog related items that always cost $300 to $650 i am going b broke being on a fixed income. ford can't fix my front end vibration i had all alignments done wheel balancing 4 times nothing helps. my steering wheel vibrates also. please help! manfred gauer . *jb
04/22/20041
 Request for reimbursement for replacement of the intake manifold. *mr the consumer was told that the manifold would only be replaced upon failure. the vehicle had been losing antifreeze. each time the vehicle was taken to the dealer, he was told that everything was fine. the manifold finally failed and was out of warranty. the dealer would not honor the open recall. the check engine light was intermittent due to a bad sensor. *sc *jb
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL - CRANKCASE (PCV)
603/01/1997
 When taking foot off the gas pedal anything that was power assisted by the engine would die out, including the engine. dealer said the air sensor valve was not working properly. *ak *ml
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - MANIFOLD/HEADER/MUFFLER/TAIL PIPE
09/06/200773500108/01/1999
 Tl*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 *bf updated 12/12/07
06/01/200757000303/01/2007
 Tl*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.
02/01/2005109/04/2000
 Dt: 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. *ak
03/03/20051
 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. *ak
09/19/2004600001
 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!*ak
04/22/20041
 Request for reimbursement for replacement of the intake manifold. *mr the consumer was told that the manifold would only be replaced upon failure. the vehicle had been losing antifreeze. each time the vehicle was taken to the dealer, he was told that everything was fine. the manifold finally failed and was out of warranty. the dealer would not honor the open recall. the check engine light was intermittent due to a bad sensor. *sc *jb
07/01/200480000110/02/1997
 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. *ak
07/06/200470600103/13/2000
 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!? *nm
800001
 Intake manifold leaks. consumer has to put coolant in the vehicle every 2 to 3 days. *ak
03/10/2004100000108/15/1997
 Intake monifold failed to contain 220 degree f engine coolant. *ak
800001
 While driving vehicle started to misfire and stall. intake manifold cracked and leaked anti freeze which caused the problem. manufacturer had an owner notification on this issue to replace the plastic intake manifold, but this vehicle not covered for two months due to vin. *ak
600001
 Per consumer vehicle is not part of the owner notification for the intake manifold coolant leak # .97m91, but vehicle is experiencing the same failure.*ak
03/02/2003572651
 Intake manifold is leaking coolant onto the engine. thid could result in an engine fire.*ak
04/18/20035120009/02/1997
 The consumer could smell anti-freeze in the cab of the vehicle. the mechanic stated that the intake manifold was cracked in two spots. *nlm
111/01/1996
 Intake manifold was recalled on vehicle, but owner was not informed when vehicle was at dealership. eight days later, vehicle shutdown on highway with no warning due to loss of coolant from intake manifold cracking. *ak *jb
01/12/2000103/01/1997
 They replaced the manifold and then the radiator malfunctioned, 18.000 miles later the heater core failed, was replaced in the last 6 months since aug 4 times. ford does not have a clue and the dealer is trying to fix it each time at leaks.the brakes/rotors have been a cronic problem since the car was new. the calipers have been resurfaced 3 times and finally replaced.*ak
11/01/199705/01/1997
 Radiator began leaking coolant. car run hot. previously engine manifold cracked. at that time(october 99), engine ran hot and smoke was coming from under hood. they replaced the manifold and then the radiator malfunctioned. the engine is now running harder and the noise level is higher. i fear that with the car overheating so many times permanent damage may have been done to the engine heads. the car is almost out of warranty and i fear i may get stuck with an engine repair job after the warranty expires. *ak
11/25/1997
 Fatigue cracks in the composite intake manifolds may result in an engine coolant leak on 4.6l sohc engines.