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
ENGINE AND ENGINE COOLING - ENGINE
981601/19/1998605565Some vehicles may stall during deceleration and / or turning with no diagnostic trouble codes (dtcs) store in continuous memory. *tt07/09/1999
987404/13/1998601343A new silicone gasket and sealant. *yc07/24/1998
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
1515808/01/2001624571Some vehicles may exhibit a fead belt jump-off toss. *yh11/07/2001
014703/05/2001619424Subject regarding engine oil recommendations for use in 2001 vehicles - sae 5w-20 motor oil. *tt05/30/2001
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 - EXHAUST SYSTEM
830004/01/2000613634Some vehicles may exhibit a bang / popping noise heard from the exhaust system during cool-down. **mr07/26/2000
1302507/01/1999610768Some vehicles may exhibit a bang popping noise heard from the exhaust system during cool-down. *tt05/12/2000
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
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL
98231011/23/1998603724Mass air flow (maf)- sensor contamination- service tip. *ak03/03/1999
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

Investigations


NHTSA IDManufacturerDate openDate closeSubjectRecall campaign
ENGINE AND ENGINE COOLING
EA02025FORD MOTOR COMPANY09/06/200206/30/2004SPEED 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

Consumer Complaints


Fail datemilesoccurencesPurchase date
ENGINE AND ENGINE COOLING
05/09/2012122000
 A crack in my exhaust manifold behind the alternator causing coolent to spray all over under my hood and now my engine overheats..thanks for using plastic parts ford .
05/09/2012122000
 A crack in my exhaust manifold behind the alternator causing coolent to spray all over under my hood and now my engine overheats..thanks for using plastic parts ford .
05/09/2012122000
 A crack in my exhaust manifold behind the alternator causing coolent to spray all over under my hood and now my engine overheats..thanks for using plastic parts ford .
12/24/20091130001
 Car caught fire had no problems with the car in the past drove about 2 miles parked and turned car off and the engine caught fire. *tr
10/21/200996000
 Tl* the contact owns a 1996 mercury grand marquis. while parked in the residence carport, the vehicle caught on fire. the fire department extinguished the flames. the massive fire completely destroyed the vehicle and caused damages to the home. there were no personal injuries. at this time the cause of failure has not been determined. the manufacturer and insurance company were notified. the failure and current mileages were 96,000.
05/18/2008713371
 Had just turned off freeway when warning chime for overheated engine sounded. stopped car within one block & turned off motor. towed to mechanic. turns out to be the intake manifold catastrophic failure, common to fords (mine is 1996 mercury grand marquis, 71k miles.) am now running compression test to see if any engine damage, if there is no damage then i will have to fix manifold at a cost of approx. $1036. if there is engine damage then i will have to junk a perfectly fine car in excellent condition (apart from this). ford does not offer any redress. i never received any information about this problem, nor about the class action lawsuit settlement. this could have been extremely dangerous, as i had just excited a freeway when the warning beep sounded. i have received all other recall info on this vehicle and have complied w. recall. in fact vehicle had been fully checked by dealer only 6 days when taken in for the second part of the switch recall on this model. dealer never informed me of any potential manifold problem. this is a safety issue as well as a defective part issue. at the very least, owners should be notified that this is a common catastrophic failure. *tr
12/07/200673000311/29/2006
 Tl*the contact owns a 1996 mercury grand marquis. occasionally, when driving 55-60 mph, the vehicle would vibrate. the vibration also occurred while driving between 35-40 mph. the contact stated that she had to add water to the antifreeze receptacle each day because the vehicle would overheat. while making a left turn, the contact would hear a rustling sound as if something was rubbing together. in addition, the rear windows would not go down. the front passenger side window would go down, but would not go back up. the contact was informed that the failure was electrical. the blinkers, brake lights, and cruise control have failed. she also received a safety recall notice for the vehicle speed control. the powertrain and recall number were unknown. the current mileage was 90,647 and failure mileage was 73,000.
08/15/2007150000107/01/2005
 Regarding my 1996 mercury grand marquis. engine fire on august 15,2007 in my driveway. key off, vehicle driven and parked 1/2 hour before incident. i received fords recall notice on sept. 4, 2007. *tr
09/16/2003556061
 1996 grand marquis intake manifold failed, mechanic determined this needed to be replaced. *ts *jb
01/06/200582160102/26/1997
 My car was not running correctly one day, so i took it to my mechanic and he found anti-freeze in the cylinders. he said that the anti-freeze blew through passage on intake manifold into the pistons, and i had to replaced the entire motor and the intake which cost me $3400.00 enable to fix. i can not understand why they used a plastic part on the motor. *nm
05/20/2005861251
 Plastic intake manifold split during travel through mountains causing all of the coolant to spew out. overheating occurred immediately and caused severe damage to engine. ford had issued a technical service bulletin 02-2-2 dated 1/17/2002 and subsequently redesigned part. this was a known problem that has not been properly communicated to the consumer resulting in extensive cost to the consumer with an engine replacement.
11/06/200486000103/16/2000
 While driving on interstate plastic intake manafold cracked, resulting in coolant spraying entire engine compartment and limiting visability. entire radiator was empty in matter of seconds. replacement part was redesigned admitting that there was a design fault in original.*ak
09/14/20041
 While driving at 45 mph, the vehicle overheated and stalled. the vehicle was towed to a independent shop. the mechanic determined the intake manifold was cracked and coolant spilled inside the engine. please provide further information. *jb
08/05/200486500102/15/2000
 Sudden loss of coolant due to a failure of the plastic intake manifold. re-placement part has been redesigned with a metal area where failure occurred. this is a common problem with this model. vehicle has 86,000 original miles on it.*ak
11/29/200389000105/12/2003
 While driving at highway speed plastic manifold intake cracked, causing the engine to lose coolant, i was told this was a problem from a ga state hero unit who stopped to give assistance. the vehicle only has 89,000 original miles, to me this is a problem and bad business on ford's part. not taking care of the customer!*ak
09/27/200373600109/06/1996
 Cracked intake manifold, causing overheating and lost of coolant while traveling at highway speed. 1996 mercury grand marquis 4.6l engine. *jb
ENGINE AND ENGINE COOLING - COOLING SYSTEM
02/25/2008102741
 Mercury grand marquis 1996 intake manifold cracked and had to be replaced, did not know there was a recall on the intake manifold until we had it replaced.
11/01/20041
 The vehicle was leaking coolant. the coolant crossover tube cracked and was spraying coolant into the alternator. it is a known problem with these vehicles. ford should have recalled these vehicles to repair them.*ak
105/15/1999
 Flames shot from under the windshield wipers and the transmission area before the entire engine caught fire. *ph vehicle showed symptoms of having hose leaking with anti-freeze before fire went off. also, the engine and fire wall was burned, consumer wasn't able to distinguish the cause of fire. *la
03/03/19961030001
 Low antifreeze level during maintenance investigation revealed cracked in plastic intake manifold. dealer indicates has seen this failure signature before. *jb
09/09/20038400010/15/2002
 September of 2003 the intake manifold blew in my car on my way to my dads funeral and i contacted the ford company about it and they said it was going to cost me 690.00 to get it fixed and i said that wasnt right. they recalled the police cars and taxi cabs with the same problem but would not recall the consumers vehicles. i told them that i knew they had brought those vehicles back so then they offered to do the job for 590.00 strange isnt it!! i got the job done but i still think that they should recall these vehicles. then today i went out to get in my car which i just drove yesterday and now it wont run again now its the computer that went out in it and it is going to cost me another 130.00 to get a new computer , this is not good this car is the first newer car that i ever owned it is a 1996 mercury grand marquis yes i know it isnt that new and yes it had alot of miles on it but they new of the problem and still should have recalled these vehicles to get them fixed . i hope you can help thank you.yes i did put 6 people got hurt but we really did because we had no way to go away because we only had 1 other vehicle and it was a chevy s10 and we could not all go away in that thanks again
09/13/2002109/01/2098
 No summary. dt
06/07/2002103/01/2098
 This catastrophic failure stranded me in the wilderness subjected to the elements. no safety defect listed. *ak
09/01/2000107/01/1996
 Engine overheated and investigation of the problem found that theplastic intake manifold developed a 3 crack right behind the alternator
09/01/2000107/01/1996
 Engine overheated and investigation of the problem found that theplastic intake manifold developed a 3 crack right behind the alternator
ENGINE AND ENGINE COOLING - ENGINE
11/27/201085218
 While driving my vehicle home from work in the evening, the car started to putter, then smoke came pouring out from under the engine hood blocking my view from the road causing cars to race around me and almost had an accident...also started coming in the vents of the car, making me nausea. extreme danger and fear. i had to have the car towed $65.00 and the repair estimate came in at $900.00. cracked plastic intake manifold. ??plastic?? who does that? i have been unemployed and only able to get part time employment. i can't afford this repair so i had to have the car towed back to my house...another $65.00. the car only has 85,218 miles on it and has been kept immaculate. i contacted mercury/ford and they said there is nothing they can do. in researching, i spent hours reading hundreds and hundreds of postings regarding the same situation...and also, the same car, ford crown victoria has the exact same problem. i understand there was a slient recall where only government fleet/police cars were taken care of. how nice! the replacement was with a metal part, which it should have been from the beginning. this is an extreme neglect on ford/mercury part. i believe that the investigation and action should be based on the quanity of both the crown victoria and grand marquis combined, since they are the exact same car manufactured. please help!
11/27/201085218
 While driving my vehicle home from work in the evening, the car started to putter, then smoke came pouring out from under the engine hood blocking my view from the road causing cars to race around me and almost had an accident...also started coming in the vents of the car, making me nausea. extreme danger and fear. i had to have the car towed $65.00 and the repair estimate came in at $900.00. cracked plastic intake manifold. ??plastic?? who does that? i have been unemployed and only able to get part time employment. i can't afford this repair so i had to have the car towed back to my house...another $65.00. the car only has 85,218 miles on it and has been kept immaculate. i contacted mercury/ford and they said there is nothing they can do. in researching, i spent hours reading hundreds and hundreds of postings regarding the same situation...and also, the same car, ford crown victoria has the exact same problem. i understand there was a slient recall where only government fleet/police cars were taken care of. how nice! the replacement was with a metal part, which it should have been from the beginning. this is an extreme neglect on ford/mercury part. i believe that the investigation and action should be based on the quanity of both the crown victoria and grand marquis combined, since they are the exact same car manufactured. please help!
11/27/201085218
 While driving my vehicle home from work in the evening, the car started to putter, then smoke came pouring out from under the engine hood blocking my view from the road causing cars to race around me and almost had an accident...also started coming in the vents of the car, making me nausea. extreme danger and fear. i had to have the car towed $65.00 and the repair estimate came in at $900.00. cracked plastic intake manifold. ??plastic?? who does that? i have been unemployed and only able to get part time employment. i can't afford this repair so i had to have the car towed back to my house...another $65.00. the car only has 85,218 miles on it and has been kept immaculate. i contacted mercury/ford and they said there is nothing they can do. in researching, i spent hours reading hundreds and hundreds of postings regarding the same situation...and also, the same car, ford crown victoria has the exact same problem. i understand there was a slient recall where only government fleet/police cars were taken care of. how nice! the replacement was with a metal part, which it should have been from the beginning. this is an extreme neglect on ford/mercury part. i believe that the investigation and action should be based on the quanity of both the crown victoria and grand marquis combined, since they are the exact same car manufactured. please help!
11/27/201085218
 While driving my vehicle home from work in the evening, the car started to putter, then smoke came pouring out from under the engine hood blocking my view from the road causing cars to race around me and almost had an accident...also started coming in the vents of the car, making me nausea. extreme danger and fear. i had to have the car towed $65.00 and the repair estimate came in at $900.00. cracked plastic intake manifold. ??plastic?? who does that? i have been unemployed and only able to get part time employment. i can't afford this repair so i had to have the car towed back to my house...another $65.00. the car only has 85,218 miles on it and has been kept immaculate. i contacted mercury/ford and they said there is nothing they can do. in researching, i spent hours reading hundreds and hundreds of postings regarding the same situation...and also, the same car, ford crown victoria has the exact same problem. i understand there was a slient recall where only government fleet/police cars were taken care of. how nice! the replacement was with a metal part, which it should have been from the beginning. this is an extreme neglect on ford/mercury part. i believe that the investigation and action should be based on the quanity of both the crown victoria and grand marquis combined, since they are the exact same car manufactured. please help!
11/01/2008700001
 Plastic intake manifold on a 1996 ford grand marquis 4.6 liter v-8. apparently there was some settlement offer from ford to replace this part with an aluminum intake however due to the car not being driven much, 70,000 miles in 12 years the intake manifold did not fail until recently. i would like to know what options i have in fixing this part and possible reimbursement of the $800 or more it will cost me to fix it. *tr
02/13/20081
 Same old story plastic intake manifold cracked lost all water cost 900.00 to fix with tow. 92,000 miles come on ford get real step up and fix this. *tr
09/06/200789021110/11/2003
 Tl*the contact owns a 1996 mercury grand marquis. while driving 35 mph, the vehicle began making a knocking noise and the contact noticed smoke rising from underneath the hood. she pulled the vehicle over and had it towed to the repair shop. the mechanic stated that the plastic intake valve melted. the purchase date was unknown. the current and failure mileages were 89,021. the dealer stated 1 set of disc pads, 2 new rotors, and clutch fan. updated 09/25/07 *tr
08/15/200739336107/01/1996
 Tl*the contact owns a 1996 mercury grand marquis. the contact started the vehicle and noticed smoke rising from the engine compartment. he then noticed that all of the coolant had leaked out of the vehicle. the vehicle was towed to a mechanic and they stated that the upper and lower intake gaskets needed to be replaced. the contact later found a recall that applied to the failures he was experiencing. the dealer stated that his vin was not included in the recall. the vehicle was repaired and the contact wants to be reimbursed. the nhtsa recall number was unknown. the failure mileage was 39,336 and current mileage was 40,000.
02/12/2007206450106/14/1999
 The intake manifold has a hairline crack on the rear heater hose inlet. anti-freeze is seeping out into the #4 spark plug causing misfiring. this plastic manifold was previously replaced before the recall to repair defective manifolds. this is the replacement manifold with a separate aluminum hot water cross over in front. *jb
08/22/2006103200111/10/1999
 I was driving my 1996 mercury grand marquis when steam started pouring from under the hood. i had to have my car towed and learned that the intake-manifold had cracked, causing coolant to pour all over the engine. the garage replaced the unit for a charge of $692 and told me everything was then fine. however, before i got home, my engine light came on. i took my car to the very reputable automobile repair shop that i use and upon checking, they said the wires, points, and plugs needed replacing, no doubt caused from the prior incident. this work cost me an additional $425.
04/18/200589816104/01/2004
 I was driving home and my car began overheating. the next day i brought it to a repair shop. they told me that the intake manifold was cracked and that there had been recalls on the engine in my car for this exact problem. they told me that there had been several instances of this repair being done under recall. they used their resources to obtain documentation of recalls being issued for this exact problem. i contacted ford motor corp. customer service and spoke with a representative who told me that my particular car had no outstanding recalls associated with it. the repeated occurence of this problem has been noted by me through several instances of customer complaints posted on the internet. the exact problem is with a plastic intake manifold which develops a crack near the themostat and leaks coolant.*ak
06/03/20048426306/01/1999
 1996 mercury grand marquis suffered intake manifold failure.*mr *nm
07/01/20041
 1996 mercury grand marquis needed a new intake manifold. *mr the consumer had concerns about the plastic manifold. the consumer requested reimbursement. *sc *jb
02/04/2004750001
 Plastic intake manifold cracked. dealer told us this was very common and would cost $977.00 to repair. this seems excessive since the car has only 75,000 miles. ford had a recall for their big customers but the little guy will take it in the shorts. this part should last for the life of the vehicle. *jb
10/03/200386899106/15/1996
 I too have recently suffered from the ford defect - intake crack at approximately 85,000 miles as so many other have with the 4.6 liter engine. the local dealers say their is currently no recall but their is an existing recall for police and taxi cabs. purchased the new style intake for approximately $450.00 and repaired myself. i will be holding on to the receipt when ford realizes they better put a recall on this to regain the trust of loyal buyers! i will also be reporting a complaint to the nhtsa. a back up email address is: rhanna@rslusa.net *la
06/01/200312000108/07/1996
 Heating cooling system = car overheated and mechanic found a cracked intake manifold. there have been quite a few complaints on this by other owners - one dealer even states this is a defective manifold. believe ford should recall these or repair them when needed as they are defective. *jb
752001
 There was a defect in intake manifold, which was described in the tsb 630628. please provide more details. *jb
03/04/20031
 The intake manifold over heated and cracked, which caused fluid to leak. *jb
1
 Consumer experiencing consistant problems with faulty intake manifold and gasket. nlm
ENGINE AND ENGINE COOLING - ENGINE - GASOLINE
790001
 While driving vehicle started vibrating. smoke started coming out from the hood, then the vehicle stalled. this was caused by a crack in the head gasket. the head gasket was replaced.*ak
06/25/20021
 Consumer states while driving there is a coolant leak and the check engine light is on. consumer is aware there is possibly a recall relating to the condition, however, dealership would not authorize possible recall. dealer found a cracked plastic intake manifold, intake gaskets and plug wires were replaced. *tt *cb
02/01/20002010/12/1996
 While driving at slow speed and without warning, vehicle will shut off, resulting in no power steering or power brakes.*ak. consumer states engine stalls frequently while turning, the engine codes are all normal, the dealer has attempted to repair the vehicle 3 times with no success.*jb
06/14/2001106/01/1996
 No summary listed for above vehicle. *ak
02/20/2001308/14/1996
 Vehicle stalls, mostly while making turns at slow speeds. dealer feels cause is overfilling of fuel filler neck. *ak dealer replaced filler pipe, however consumer states vehicle is still stalling. *slc
06/26/200014
 While driving about 20 mph vehicle stalled. there was no power steering and brakes, vehicle is at repair shop for the fourteenth time.*ak
1
 The vehicle shudders and vibrates when traveling in 3rd and 4th gear and then looses power. nlm
 Fast idle--800 rpm at neutral. self-accelerates on flat surface up to 9 mph.
1
 Engine failed.
03/18/1996
 Noticed drive train vibrating and shaking progressively worse at 70mph.
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM
11/27/201085218
 While driving my vehicle home from work in the evening, the car started to putter, then smoke came pouring out from under the engine hood blocking my view from the road causing cars to race around me and almost had an accident...also started coming in the vents of the car, making me nausea. extreme danger and fear. i had to have the car towed $65.00 and the repair estimate came in at $900.00. cracked plastic intake manifold. ??plastic?? who does that? i have been unemployed and only able to get part time employment. i can't afford this repair so i had to have the car towed back to my house...another $65.00. the car only has 85,218 miles on it and has been kept immaculate. i contacted mercury/ford and they said there is nothing they can do. in researching, i spent hours reading hundreds and hundreds of postings regarding the same situation...and also, the same car, ford crown victoria has the exact same problem. i understand there was a slient recall where only government fleet/police cars were taken care of. how nice! the replacement was with a metal part, which it should have been from the beginning. this is an extreme neglect on ford/mercury part. i believe that the investigation and action should be based on the quanity of both the crown victoria and grand marquis combined, since they are the exact same car manufactured. please help!
11/27/201085218
 While driving my vehicle home from work in the evening, the car started to putter, then smoke came pouring out from under the engine hood blocking my view from the road causing cars to race around me and almost had an accident...also started coming in the vents of the car, making me nausea. extreme danger and fear. i had to have the car towed $65.00 and the repair estimate came in at $900.00. cracked plastic intake manifold. ??plastic?? who does that? i have been unemployed and only able to get part time employment. i can't afford this repair so i had to have the car towed back to my house...another $65.00. the car only has 85,218 miles on it and has been kept immaculate. i contacted mercury/ford and they said there is nothing they can do. in researching, i spent hours reading hundreds and hundreds of postings regarding the same situation...and also, the same car, ford crown victoria has the exact same problem. i understand there was a slient recall where only government fleet/police cars were taken care of. how nice! the replacement was with a metal part, which it should have been from the beginning. this is an extreme neglect on ford/mercury part. i believe that the investigation and action should be based on the quanity of both the crown victoria and grand marquis combined, since they are the exact same car manufactured. please help!
11/27/201085218
 While driving my vehicle home from work in the evening, the car started to putter, then smoke came pouring out from under the engine hood blocking my view from the road causing cars to race around me and almost had an accident...also started coming in the vents of the car, making me nausea. extreme danger and fear. i had to have the car towed $65.00 and the repair estimate came in at $900.00. cracked plastic intake manifold. ??plastic?? who does that? i have been unemployed and only able to get part time employment. i can't afford this repair so i had to have the car towed back to my house...another $65.00. the car only has 85,218 miles on it and has been kept immaculate. i contacted mercury/ford and they said there is nothing they can do. in researching, i spent hours reading hundreds and hundreds of postings regarding the same situation...and also, the same car, ford crown victoria has the exact same problem. i understand there was a slient recall where only government fleet/police cars were taken care of. how nice! the replacement was with a metal part, which it should have been from the beginning. this is an extreme neglect on ford/mercury part. i believe that the investigation and action should be based on the quanity of both the crown victoria and grand marquis combined, since they are the exact same car manufactured. please help!
11/27/201085218
 While driving my vehicle home from work in the evening, the car started to putter, then smoke came pouring out from under the engine hood blocking my view from the road causing cars to race around me and almost had an accident...also started coming in the vents of the car, making me nausea. extreme danger and fear. i had to have the car towed $65.00 and the repair estimate came in at $900.00. cracked plastic intake manifold. ??plastic?? who does that? i have been unemployed and only able to get part time employment. i can't afford this repair so i had to have the car towed back to my house...another $65.00. the car only has 85,218 miles on it and has been kept immaculate. i contacted mercury/ford and they said there is nothing they can do. in researching, i spent hours reading hundreds and hundreds of postings regarding the same situation...and also, the same car, ford crown victoria has the exact same problem. i understand there was a slient recall where only government fleet/police cars were taken care of. how nice! the replacement was with a metal part, which it should have been from the beginning. this is an extreme neglect on ford/mercury part. i believe that the investigation and action should be based on the quanity of both the crown victoria and grand marquis combined, since they are the exact same car manufactured. please help!
09/08/1998
 Vehicle is driven in bahrain where unleaded fuel is unavailable. does owner need to replace part of the exhaust system and the engine electronic processor?
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL - CATALYTIC CONVERTOR
08/04/200590473106/21/2002
 Dt: while driving the brake lines failed and had to be replaced. the owner came outside and saw the brake fluid on the ground and realized that the brake lines failed. the owner drove the vehicle with no brakes to the dealership and they repaired it. then the owner realized that the brake lines were rusted.*ak the left rear seat belt was replaced twice. the wiper motor, wiper switch, drivers side mirror switch and rotors were all replaced. the turn signal switch, driver window switch , tail light , catalytic converter were replaced. the consumer was told the ball joints and shocks were bad. the battery was replaced. *jb
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - MANIFOLD/HEADER/MUFFLER/TAIL PIPE
02/17/2006987971
 Dt*: the contact stated the temperature gauge became inoperable, and while attempting to repair a leak in the intake manifold was noticed. the vehicle was taken to an independent repair shop where the intake manifold was replaced. there have been no further problems. *ak
08/15/20051
 Dt: the vehicle had problems with the intake manifold. the car was smoking while driving. the intake manifold was cracked. the vehicle had 90,000 miles on it. the owner was aware this was not a safety problem. the owner was upset with the dealership.*ak
04/24/200560102110/08/1999
 1996 mercury marquis ,,cracked composite intake head...$ 1100.00 repaired. i understand there was a fleet recall for this, but not for personally owned vehicles.i feel cheated...the composite heads are defective. *ak
06/17/2004883731
 Complaint received via e-mail. we just had our plastic intake manifold replaced, costing $852.28. after so many miles, the pressure makes the front end of the manifold crack and leak. our mechanic has replaced many of these faulty plastic manifolds ,and he said eventually all early models of the mercury grand marquis will have to have this part replaced. he said the ford company has replaced this manifold on later models, starting with 2002 with an aluminum part where the problem was. *ak *tc
07/29/2004700001
 Intake manifold on 1996 mercury grand marquis failure.*ak
10/13/20041320001
 Intake manifold had to be replaced. the manufactured manifold is made of some sort of plastic. the replacement manifold is also made of the same sort of plastic, but has been revised. lincoln mercury considers the new manifold improved. the new one has an aluminum metal on the front section of manifold where alternator support bracket bolts in to hold back of alternator. speaking to many garages dealing with these same type of vehicles it was stated that this is a common problem with these types of vehicles. reasoning believed to be is from the vibration of alternator bracket where it bolts into the intake manifold. the intake manifold between the 2 mounting bolts of the alternator bracket cracked across the 2 bolts. *ak
09/10/20041100001
 Consumer noticed that vehicle was leaking coolant. vehicle was taken to an independent repair shop, and mechanic determined the intake manifold cracked and coolant spilled inside the engine. mechanic indicated the need to replace the intake manifold. *ak *nm
09/05/200468800102/26/1996
 My car intake cracked. the car dealership informed us that there was a recall of police vehicles by mercury/ford for this problem but not to consumers. *ak
06/20/20041
 While driving 55 mph consumer noticed smoke coming from the front of the vehicle. consumer was able to maintain control of the vehicle, and pulled over. vehicle was towed to the dealer for inspection, and mechanic determined that the intake manifold was cracked and needed to be replaced. *ak
07/05/2004127992106/09/2000
 My car (1996 mercury grand marquis) developed a crack in the intake manifold leading to complete loss of coolant and overheating while traveling through wyoming. it was then towed to a small town repair shop, where this problem was brought to my attention, and that many cars had a recall for this. unfortunately, for civilian cars there is no recall which led to a repair cost of $1132.00. *la
04/17/200484000101/01/2000
 While driving 50 mph smoke came from underneath the hood. the dealer stated that the intake manifold cracked. *ak *nm
04/02/2004830001
 While driving 50 mph vehicle overheated. dealership informed the consumer that the problem pertained to cracks in the intake manifold. the problem was not resolved. *ak
03/20/200478125103/30/1996
 Intake manifold made of plastic and it cracks. replacement has metal where plastic was used, obvious a design defect.*ak
03/15/2004750001
 While driving consumer noticed head gasket was leaking coolant. the intake manifold was replaced at consumer's expense. *ak *nm
02/15/200470046104/20/1999
 Consumer took the vehicle to dealership for inspection, and mechanic determined that plastic intake manifold cracked, causing fluid to leak onto the engine. *ak this led to the blew up of coolant in the motor and over heating of the vehicle. service dealer replaced intake manifold. *la
11/12/200384103/12/1999
 Intake manifold failure.*ak
72000108/28/1996
 Plastic intake manifold cracked causing premature damage to vehicle.*mr consumer stated ford was aware of the failure because they entered a recall to fleet owner's only. this included taxi cabs, and all police departments. there was no restriction on mileage. ford has made the crossover pipe of the new manifolds out of aluminum. consumer contacted the dealer and was told the vin wasn't recall and it wasn't under warranty. *ph *nlm
900001
 Intake manifold cracked, causing vehicle to overheat and stall while driving. dealership indicated that manifold cracked because it's made of plastic.*ak
01/31/20031150001
 While driving down a major highway, the manifold cracked and a cloud of smoke come out from behind my car. i thought it was just a hose. after having it towed to a repair station, i found out that the manifold had cracked and that it was made out of plastic. it cost over $500 to fix it. *la
09/05/200360000108/01/2001
 1996 mercury grand marquis, which has a plastic intake manifold, started leaking coolant over the front of the engine. plastic cracked in front section allowing coolant loss to spray all over. visited local dealer, palm beach lincoln-mercury who admitted this is a common problem and is recalled on some newer models but there is not recall, free or paid replacement on this item. repairs cost in excess of $800.00 to have the intake manifold replaced. please commence investigation as there are numerous other complaints on nhtsa site for same item. *jb
870001
 The plastic intake manifold cracked and leaked anti freeze all over the engine compartment. this resulted in the vehicle overheating while driving at highway speed. *ak
08/18/200312700001/25/2000
 Plastic intake manifold cracked 4 inch crack behind distributor. *nlm
07/01/200372500108/30/1996
 While driving and without any indication smoke started coming from under the hood. the technician serviced the vehicle and noticed the manifold was cracked. *ak *scc *jb
06/15/200354000112/01/1995
 Consumer stated intake gasket failed. dealer notified.*ak. the consumer stated while driving, he smelled antifreeze and noticed the vehicle started to overheat, the vehicle was towed to the dealer who stated the part was a manufacturing defect, because the intake manifold used to be made of cast iron and now it is made of aluminum. *jb *scc *jb
06/23/2003102729105/29/1996
 Sudden loss of engine coolant due to failure of plastic intake manifold behind alternator.*ak
06/15/200377000103/07/2000
 While driving manifold cracked, causing a fire in the fuel tank. dealer notified. *ak while driving the manifold cracked which caused antifreeze to leak from the vehicle. the dealer indicated that the manifold was a defective part and that they replaced many of them with the same type of failure. *scc *nlm
2
 The vehicle experienced intake manifold problems. *ak *jb
01/20/20038686708/03/1996
 Manifold cracked allowing antifreeze to splash over engine. do not understand why they would make a manifold out of plastic given the cooling and heating area of the engine. understand there have been several complaints, one in which a dealer apparently stated that the manifold was defective and this is a common problem with the vehicle.
11/19/200259000112/19/1996
 While driving, the manifold cracked and antifreeze splashed all over the motor, which caused a considerable amount damage to the engine. dealer was contacted and stated the manifold was faulty and was a common problem with this model/year. ts scc *jb
10/12/2002
 Consumer states, while driving vehicle noticed a smoke under the hood. plastic manifold was causing the burning and damaging engine. dealer has been notified. provide further information. ts
10/06/2002110/01/1996
 The plastic manifold cracked, which caused the vehicle to overheat.mr *jb
06/22/2002101/01/2000
 Plastic intake manifold cracked behind the alternator, causing coolant leakage. *ak
11/01/2000104/01/1996
 I checked through the service bulletins and complaints-there are several other complaints with these manifolds- not sure why they are making parts out of plastic-is this normal since it involves the coolant-heating area of the vehicle? this cost me 721.56.*ak
04/01/19982
 Cracks in the plastic intake manifold. mjs