Bulletins
| Bulletin | Bulletin date | Replacement Bulletin | Item no. | Summary | Added |
|---|---|---|---|---|---|
| ENGINE AND ENGINE COOLING | |||||
| 0222 | 02/04/2002 | 630628 | Some vehicles may exhibit an intake manifold crossover (first runner) coolant seepage condition. *tt | 04/19/2002 | |
| 99B29 | 12/01/1999 | 612219 | Some vehicles may experience engine coolant leaks at the engine front cover gasket. owner notification program providing replacement of the engine front cover gasket. *tt | 06/07/2000 | |
| 13186 | 09/01/1999 | 6090542 | Information regarding front cover & water pump bolts-torque valve revision/3.8-4.2l. *mjs | 03/21/2000 | |
| 99207 | 10/04/1999 | 6089651 | Subject on engine coolant leaking into the engine oil on some vehicles. *tt | 02/11/2000 | |
| 99131 | 06/28/1999 | 606484 | Concerns with engine coolant leaking into engine oil on some vehicles. *tt | 08/25/1999 | |
| 97050110617 | 05/01/1997 | 52896 | Vehicles may experience illumination of the engine cooling indicator light. *tw | 10/30/1997 | |
| ENGINE AND ENGINE COOLING - COOLING SYSTEM - HOSE | |||||
| BC3243970210 | 02/10/1997 | 51865 | Engine cooling light on - possible oil leak at upper jam nut on the upper transmission cooler line. *tw | 07/17/1997 | |
| ENGINE AND ENGINE COOLING - ENGINE | |||||
| 02221 | 11/11/2002 | 10008304 | Engine-gear driven synchronizers-incorrect installation-camshaft position synchronizer (cmp) installation tool correct application. *mj | 07/27/2004 | |
| 870197 | 10/22/2002 | 10000592 | Incorrectly 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. *tt | 03/25/2003 | |
| 99B29#1 | 04/01/2000 | 99B29 | 613562 | Information regarding replacment of engine front cover gasket. **mr | 07/21/2000 |
| 6996 | 09/01/1999 | 6090309 | Information regarding a change in the torque values of the engine front cover water pump bolts. *tt | 03/14/2000 | |
| 983224 | 02/12/1998 | 607436 | Some vehicles may have water contamination in the air filter and / or the mass air flow sensor. *tt | 09/23/1999 | |
| 9874 | 04/13/1998 | 601343 | A new silicone gasket and sealant. *yc | 07/24/1998 | |
| 97610 | 03/17/1997 | 51990 | Blower motor- chirping or squeaking from blower motor at low speeds. *jd | 07/17/1997 | |
| BC0990961021 | 10/21/1996 | 50442 | Information on engine oil leak at the oil pan, front cover &/or the front & rear crankshaft oil seal. *tt | 04/24/1997 | |
| ENGINE AND ENGINE COOLING - ENGINE - GASOLINE | |||||
| 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 | |
| 0147 | 03/05/2001 | 619424 | Subject regarding engine oil recommendations for use in 2001 vehicles - sae 5w-20 motor oil. *tt | 05/30/2001 | |
| 4643 | 08/01/1998 | 615181 | Some vehicles may exhibit an rpm flare on a forced 4/2 downshift. additionally, the commanded electronic pressure control is at appromately 10 psi. *tt | 01/03/2001 | |
| 983108 | 02/01/1998 | 607402 | Effective march 2, 1998m3.8l engine assembly is added to fqr(ford quality renewal) assembly program. *ak | 12/21/2000 | |
| 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 | |
| ENGINE AND ENGINE COOLING - ENGINE - GASOLINE - BELTS AND ASSOCIATED PULLEYS | |||||
| BC3288970206 | 02/06/1997 | 51884 | Vehicles may exhibit a cold start engine fead belt chirp noise. *tw | 07/17/1997 | |
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM | |||||
| 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 | |
| BC0490961112 | 11/12/1996 | 50763 | Instructions for replacing diagnosed failed component. *tw | 06/17/1997 | |
| BC9714961101 | 11/01/1996 | 50860 | Diagnostic instructions for servicing evaporative emission purge flow system. *tw | 06/17/1997 | |
| BC0407961115 | 11/15/1996 | 50753 | Instructions for replacing diagnosed failed parts. *tw | 06/17/1997 | |
| 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 | |
| 9834 | 02/16/1998 | 600588 | Air 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. *ak | 05/27/1998 | |
Consumer Complaints
| Fail date | miles | occurences | Purchase date |
|---|---|---|---|
| ENGINE AND ENGINE COOLING | |||
| 02/01/2011 | 61000 | ||
| Tl-the contact owns a 1996 mercury cougar. the contact stated that the climate control adjuster failed. as a result, the blower would only function on high and the contact was unable to adjust the defrost system. the vehicle was taken to an authorized dealer to have the failure diagnosed, but they were unable to duplicate the failure. the vehicle was not repaired. the approximate failure mileage was 61,000 and the current mileage was 62,000. the vin was unavailable. sm. | |||
| 02/01/2011 | 62000 | ||
| Tl-the contact owns a 1996 mercury cougar. the contact stated the climate control adjuster failed causing the blower only to operate on high and was unable to adjust to the defrost system. the vehicle was unable to duplicate the failure. the vehicle has not been repaired. the current mileage was 62,000. the approximate failure mileage was 61,000. the vin was unavailable. bw | |||
| 12/25/2010 | 140000 | ||
| Tl - the contact owns a 1996 mercury cougar. the contact stated that her vehicle was leaking anti freeze. the vehicle was taken to local shop who advised that the plastic intake manifold was crack and needed to be replaced. the vehicle was not repaired. the manufacturer was not contacted. the failure and current mileage were 140,000. pm | |||
| 05/29/2005 | 12918 | 2 | 03/28/2001 |
| Campaign 96v007000----on my 96 cougarxr7 purchased in 2001--had to repace motor due to overheating--new motor started to overheat/blower caused this over-heating--because blower came on eratically mechanic did not find immediately//currently out of pocketexpenses around 6000.00--dealer should of had this fixed before selling to me or at least notified me of this recall | |||
| 07/01/2004 | 5 | ||
| Problems with vehicle's intake manifold. *mr one week before the intake manifold problem the vehicle was in for a problem with the back up and brake lights, the fan belt, and the vehicle over heated after attempting to pass another vehicle on the highway. *sc *jb | |||
| 02/15/2003 | 0 | ||
| I bought a mecury cougar xr7 feburary 1st, 2003 at carmax in dulles, va. i have had the car approximately 3 weeks. last monday february 10, 2003 i took my car to inspected by the state of maryland. i was assured this car would pass inspection. my car failed inspection. i am now having engine problems with my car where it jumps and knocks. the engine light goes on and off. i have tried calling carmax several times this week to get my car repaired at their laurel dealership and where i bought my car at carmax in sterling/dulles, va. no one could help me to bring my car in or set up an earlier appointment. my car sounds like it is going to fall apart. my girlfriend called the salesperson saturday february 15, 2003. the salesperson called the operations manager and he called my girlfriend. they are trying to set up a time for me to bring my car in on monday. i have called all week and no one would forward my call to the operations manager at carmax. my appointment was set up to bring my car in on february 24th. i am worried that i bought lemon. i only had the car approximatley 3 weeks. there is a certificate in my car from virginia state claiming that this car passed inspection back in december of 2002. | |||
| 26701 | 1 | 09/01/1996 | |
| There was a loud knocking noise from under the hood, and had taken the vehicle to several people and was told that it was something internal and will need a new engine. the consumer would like to know if there was a defect in the manufacturing. *scc | |||
| ENGINE AND ENGINE COOLING - COOLING SYSTEM | |||
| 10/02/2005 | 100109 | 1 | 10/01/2004 |
| I was driving and saw my low coolant light was on. pulled into car parts company parking lot. opened hood saw coolant on top of motor and underside of hood. coolant was leaking from front of the intake manifold. upon inspection realized the manifold is made of plastic. i attempted to stop the leak with plastic repair and a coolant system repair, no use. had to limp the car to zender ford in spruce grove, alberta. they are fixing the car at an estimated cost of $900.00 no warranty or recall. left me stranded 400 km's from my home. *nm | |||
| 10/09/2004 | 95000 | 1 | 10/09/2004 |
| I just purchased vehicle from used car lot. during my 3 mile trip home the car over heated and water vapor was coming in through air conditioning vents. when i stopped at my home, i could see steam coming from inside engine. when i opened the hood, i found that there was crack in a plastic part coming directly off of the engine block to a coolant hose. i went to several auto parts stores to identify the part and found it was a crack in the intake manifold water cross-over jacket causing coolant leak. the stores did not carry a replacement, so i called the ford dealership. ford does have a replacement part, actually they redesigned the whole intake manifold because of their poor design error. they also had extended the car warranty to 7 years to replace this part if/when failure occurs. the ford replacement is an assembly, not part just the problem part, it costs $589.17 and dealer installation of it costs $450.00. ford would not assist or give at all on the 7 year warranty extension to fix their obvious design flaw in the part and/or the whole assembly. through on-line newgroups about this problem, junkyards cannot keep the old plastic part in their yards. i love the cougar xr7 v8, but beware if this part hasn't been fixed with the new one, that you will at some point have to fix it. *nm | |||
| 08/25/2003 | 1 | ||
| Temperature gauge went up, car overheated. took vehicle to independent shop, and technician stated that intake plastic manifold cracked.*ak | |||
| ENGINE AND ENGINE COOLING - COOLING SYSTEM - FAN | |||
| 06/23/1996 | 1 | 03/10/1996 | |
| Fan cut the computer wires. | |||
| ENGINE AND ENGINE COOLING - ENGINE | |||
| 09/12/2007 | 40359 | 1 | |
| 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. *cn | |||
| 04/05/2006 | 80000 | 1 | 06/11/1998 |
| 1996 mercury cougar v6 3.8 liter engine. head gasket failure. this engine has never overheated. roughly 80,000 miles. $1200-1500 estimate for repair. *nm | |||
| 11/22/2004 | 07/24/1996 | ||
| 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. *nm | |||
| 03/25/1998 | 3 | 07/29/1996 | |
| Engine idle pulley replaced. | |||
| 1 | 07/29/1996 | ||
| Replaced weak motor mount. | |||
| ENGINE AND ENGINE COOLING - ENGINE - GASOLINE | |||
| 06/01/2002 | 1 | 06/01/2001 | |
| 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 | |||
| 0 | |||
| The consumer had a recall for engine. dealership replaced defective part from recall. six month later, replacement part didn't work. dealership mechanic told her that she needed a new engine. engine light came on while consumer was driving. and stayed on. she complained that engine coolant was running out from underneath vehicle. vehicle wouldn't move. vehicle had to be towed. consumer was concerned that replacement part didn't work at first, and she needed some help from ford motor company.*ak | |||
| Top of engine, made out of plastic ,developed a tear in it.consumer ordered new part which is now revised and made of stronger material. *ak | |||
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM | |||
| 02/15/2003 | 0 | ||
| I bought a mecury cougar xr7 feburary 1st, 2003 at carmax in dulles, va. i have had the car approximately 3 weeks. last monday february 10, 2003 i took my car to inspected by the state of maryland. i was assured this car would pass inspection. my car failed inspection. i am now having engine problems with my car where it jumps and knocks. the engine light goes on and off. i have tried calling carmax several times this week to get my car repaired at their laurel dealership and where i bought my car at carmax in sterling/dulles, va. no one could help me to bring my car in or set up an earlier appointment. my car sounds like it is going to fall apart. my girlfriend called the salesperson saturday february 15, 2003. the salesperson called the operations manager and he called my girlfriend. they are trying to set up a time for me to bring my car in on monday. i have called all week and no one would forward my call to the operations manager at carmax. my appointment was set up to bring my car in on february 24th. i am worried that i bought lemon. i only had the car approximatley 3 weeks. there is a certificate in my car from virginia state claiming that this car passed inspection back in december of 2002. | |||
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - MANIFOLD/HEADER/MUFFLER/TAIL PIPE | |||
| 12/17/2001 | 36654 | 9 | |
| Check for coolant leak at intake manifold. replaced intake manifold. there were regular oil changes and tire rotation. *bf 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. *sc | |||
| 09/12/2004 | 275000 | 2 | |
| Intake manifold has developed a crack. as a result, water leaked out, and the engine overheated. *ak | |||
| 10/10/2003 | 89805 | 1 | |
| 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? *la | |||
| 08/31/2003 | 80000 | 1 | 03/01/2002 |
| 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.*ak | |||
| 12/24/1999 | 1 | 10/01/1998 | |
| 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? | |||