Cracked intake manifold.

- Marion, AR, USA

I would like to inform you about a safety problem with certain Lincoln Town car models. I am the owner of a 1996 Lincoln Town car (signature series). On June 16, 2006, while driving in town with the air conditioning on, I saw smoke pouring from under the hood and antifreeze leaking from under the car. After opening the hood I saw antifreeze all over the engine block. I managed to drive the car to a nearby jiffy lube. The technician there could not find any leaks in the hoses or the radiator. After allowing the car to cool for about thirty minutes, the technician filled the radiator with a 50-50 antifreeze-water mixture. I started driving home, about five miles away. Before I arrived, the temperature gauge reached the maximum point, and the high-temperature alarm sounded. I immediately stopped the car and opened the hood. Again, I saw antifreeze all over the engine. When the car had cooled, I checked the coolant level: It was completely dry! I had the car towed to a local garage, where the mechanic found a two-inch crack at the rear of the intake manifold! this mechanic told me that a large number of Ford vehicles had experienced a similar problem with intake manifolds, which were fabricated from plastic, rather than metal. He said that dozens of North Carolina highway patrol cars (crown victorias equipped with the same 4.6-liter engine that's in my Lincoln) had been recalled because of defective intake manifolds. This kind of problem warrants a safety recall. Imagine what could happen if a car being driven on an interstate were to suddenly lose all of its coolant from a leaking intake manifold! in view of the safety hazards a leaking intake manifold can (and does) create, I believe that Ford Motor Company should reimburse me for the costs I incurred for a new manifold and the labor to install it. (I kept the defective manifold, in case you want to inspect it.)

- Durham, NC, USA

Service manager stated that the intake manifold "blew" while checking engine RPM, resulting in loss of coolant and engine failure. Further stated that his facility had replaced 30 defective plastic intake manifolds so far this year, 16 since April. He indicated that Ford motor will replace at no cost to taxicab, police, and Ford thunderbird owners, but not to individual out of warranty owners. Cost to replace by the dealers book including labor $1241 design defect : intake manifold in replacement part changes the front coolant transfer section with metal section instead of plastic. Rear section that transfers coolant also is not changed, remains plastic. When is projected failure of rear plastic coolant part as this vehicle only had 59,126 miles on the odometer at the time of failure. ? I have retained the defective intake manifold and have documented with photo graphs the defective section with replacement part labels.

- Tampa , FL, USA

While driving at highway speed temperature gauge went to maximum, and the intake manifold blew. This caused anti freeze to spread onto engine without warning.

- Port Saint Lucie, FL, USA

The plastic intake manifold cracked and leaked coolant onto the engine.

- Corona, CA, USA

Ford has a history of composite intake manifold failures on their 4.6L V-8 engines. The crack, noted by Ford, is on the first crossover directly behind the alternator. The leaking freeze sprays all ove the engine's electrical system and causes the engine to stop. This sudden loss of power could cause unnecessary accidents. Ford, at present, does not offer an entended warranty on this design failure.

- Kinnelon, AK, USA

While vehicle was parked consumer noticed that coolant was leaking underneath the vehicle. Dealership was aware of problem.

- Saraota, FL, USA