Ford designed the A/C drain line located above the right exhaust pipe leading to the catalytic converter on the 3.8 liter V6 engine. The cold condensation from the A/C dripping onto the pipe causes the pipe to crack or in some cases causes the catalytic converter to rupture or crack. This is an expensive repair. I know of 3 people in my business that this has happened to in just the past 6 months. One case the converter had to be replaced and in the other 2 the exhaust pipe had to be removed and welded at the cracks. Stainless steel pipes are welded different then the old steel pipes and require a special welding technique and equipment driving up the cost of the repair. This crack left unattended could lead to carbon monoxide entering the cockpit area.

- Sebastian, FL, USA

Owner was complaining that the engine light keeps coming on. Owner took the vehicle to the dealer and was told that they were not responsible. Owner took the vehicle to another dealer and was told that the catalytic converter had been removed causing the vehicle to shut down due to excessive heat. Provide further details.

- Naples, FL, USA

Engine failed after owning car for only 2 weeks. Car died in the middle of an intersection. Tow truck picked it up, and dealership said that the engine harness was not properly wired. Air conditioning made loud noises when running. Dealership said that the water was dropping directly on to the 1500 degree exhaust pipe causing the loud noise. Because the heat shield wasn't properly functioning, dealership placed a pipe underneath to divert the water.

- St. Petersburg, FL, USA

Engine failed after owning car for only 2 weeks. Car died in the middle of an intersection. Tow truck picked it up, and dealership said that the engine harness was not properly wired. Air conditioning made loud noises when running. Dealership said that the water was dropping directly on to the 1500 degree exhaust pipe causing the loud noise. Because the heat shield wasn't properly functioning, dealership placed a pipe underneath to divert the water.

- St. Petersburg, FL, USA

While driving fumes would come inside through passenger's compartment. This would cause driver to get headachs & nausea. Fumes were carbon monoxide. Have taken to dealership 3 times, each time mechanic could not solve problem. The dealer could not fix the problem but the fume created considerable health problems to the consumer.

- Mc Keesport, PA, USA

Converter glowing orange and making noises equivalent to hammer hitting metal. Heat can be felt coming through driver's side floor board to the point that it feels as though heater is on high. Was told this is normal, converters run up to 1800 degrees, and should only be concerned if it hits 2000 degrees. How am I supposed to know what temperature it's running?

- Houston, TX, USA