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 and the repair estimate came in at $900. 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. 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 "silent 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 quantity of both the Crown Victoria and Grand Marquis combined, since they are the exact same car manufactured. Please help!

- Murrells Inlet, SC, USA

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.

- Fort Pierce, FL, USA

Same old story plastic intake manifold cracked lost all water cost $900 to fix with tow. 92,000 miles come on Ford get real step up and fix this.

- Monticello, MN, USA

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

- Mcminnville, TN, USA

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.

- Arlington, MA, USA

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.

- Schertz, TX, USA

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.

- Mobile, AL, USA

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.

- League City, TX, USA

1996 Mercury Grand Marquis suffered intake manifold failure.

- Boulder City, NV, USA

1996 Mercury Grand Marquis needed a new intake manifold. The consumer had concerns about the plastic manifold. The consumer requested reimbursement.

- Glendale, NY, USA

Plastic intake manifold cracked. Dealer told us this was very common and would cost $977 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.

- Peoria, AZ, USA

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 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

- New Kensington, PA, USA

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.

- Rockville, IN, USA

There was a defect in intake manifold, which was described in the tsb 630628.

- Abita Springs, LA, USA

The intake manifold over heated and cracked, which caused fluid to leak.

- Van Nuys, CA, USA

Consumer experiencing consistant problems with faulty intake manifold and gasket. Nlm

- Stone Moun, GA, USA