The intake manifold for 4.6L engines are plastic and has been a problem since 1996 when they were recalled and Ford still used the plastic manifold anyway. My manifold cracked right behind the alternator spewing antifreeze all over the engine compartment. This has been a problem and Ford will not cover the repair or change the manifolds.

- Spring City, PA, USA

Consumer states that the intake manifold is cracked causing leaks.

- Drexel Hill, PA, USA

Consumer notice coolant smell inside vehicle while traveling soon after notice temperature gauge rising with indication light flashing. Consumer pull vehicle over look under hood and notice coolant under hood and ground vehicle was service intake manifold need to be replace. Mr the consumer states that Ford acknowledges this problem to fleet owners and has a recall, but aren't addressing the problem. The consumer states that he has made the repairs with parts purchased from the Ford dealer. (cracked along the seam, dumped coolant all over the upper engine and onto the ground)

- Modesto, CA, USA

The plastic intake manifold ruptured causing coolant to enter the cylinders and may have caused crack in engine block.

- Inverness, FL, USA

Plastic intake manifold ruptured causing coolant to further enter cylinders and may have caused crack in engine block-this vehicle has been exceptionally well cared for including oil changes each 2000 miles-Ford & co have essentially said I'm on my own-this integral part should certainly have been manufactured to a greater and not a minimal standard.

- Inverness, FL, USA

Plastic intake manifold split, causing coolant to enter into cylinders and appears may also have cracked engine block-seems Ford & co could care less-this vehicle has otherwise been extremely well cared for including oil changes every 2000 miles.

- Inverness, FL, USA

I purchased this vehicle which had 86,715 miles on it. Shortly after the purchase I noticed the engine would spark knock anytime the car was put under a load when the transmission was in high gear and in overdrive. Due to my schedule I did not take the car in for this problem until the drivers side window fell down while attempting to roll it down. After spending 741 dollars to repair those problems I drove the car approximately 50 miles and steam came from under the hood. The car was towed back to the dealer. The dealer evaluated the problem and advised me that the intake manifold was broken. I was advised the repair cost was $893.75 including towing. Iwas advised by both the dealer and the Ford customer service line 1-800-392-3673 that there was no recall or warrenty for this problem. By finding this web site I have found 16 other simular conplaints.

- Fayetteville, GA, USA

Consumer states because of a design defect, heat builds up in a plastic manifold which caused a crack. Consumer is suggesting the plastic manifold has to be replaced with an aluminum-reinforced manifold.

- Roselle, IL, USA

Intake manifold is plastic, new part half cast alum(front section)only called Ford defect was changed in yr.2000 but not a recall, ?? why dealer said has replaced quite a few of these Ford mich. Said the same thing but no recall why!!!!!.

- Cookeville, TN, USA

While driving 35 mph, the consumer noticed steam coming from underneath the hood. The consumer then contacted the dealer, who determined that the plastic intake manifold had overheated, which created an antifreeze leak. The consumer states that the plastic manifold had cracked and was replaced with a metal one. The bill and the letter sent to rda group and Mercury is attached, regarding the faulty part and the request for reimbursement.

- Cookville, TN, USA

Coolant is leaking from intake manifold. Dealer contacted. Feel free to provide any further information.

- Marietta, GA, USA

Intake manifold required replacing. It had split across the front seam causing antifreeze to spill all over the engine. Our VIN number is not on the recall list even though others of the same make are. The split was across the front seam of the plastic manifold. New ones have aluminum liners in them, which makes me believe that the company knows that it`S a current problem.

- Coventry, CT, USA

Ford Motor Company recognizes several vehicles affected by this condition, including the Crown Victoria, mustang, Lincoln town car, and Mercury Cougar, all with the 4.6L engine built with a plastic intake manifold, yet Ford refuses to acknowledge the Grand Marquis. Fortunately, our experienced failure occurred at a low speed (approximately 20-25 miles per hour) as my wife was driving into our subdivision. However, the amount of steam (which she immediately thought was "smoke") caused her to panic and nearly flee the vehicle. Had this occurred at highway speeds in traffic, this failure surely could have caused a potentially harful, even fatal incident. Ford has admitted the failure, but evidently does not consider it of noteworthy concern for most vehicles equipped with this popular and widely used engine package. (see Ford document #97M91) it is frustrating that they are unwilling to correct the problem, especially since it is a known and acknowledged defect with the engine in question. This is a costly and potentially harmful, if not potentially life-threatening defect. The super-heated steam produced by the rupture at the top of the engine (right behind the fan, no less) billowed out in a plume of steam that made road-vision nearly impossible, not to mention causing a definitely distracting panic situation! I have contacted Ford, including my local dealership (moyer Ford, foley Alabama), their custuomer service "hotline" and jonathan grimm at Ford whq. All have repeated the mantra, "we're sorry, but we can't do anything for you in this situation." On the internet, I have found numerous similar complaints, and a local mechanic has stated that he has had to replace a number of the plastic manifolds as well. I feel this is a potentiall serious problem that Ford is willing to ignore! I want to call attention to this matter for the potential safety of others, as well as to reclaim the costs of repairing an admitted defect in Ford's design and manufacturin

- Foley, AL, USA

While driving, smoke began to come from under the hood, vehicle was taken in to a mechanic and consumer was infomred that the intake manifold had cracked.

- Lake Ronkonkoma, NY, USA

The vehicles intake manifold developed a 4 1/2 inch crack at the front edge. This crack caused a total loss of all coolant.

- Miami, FL, USA

Intake manifold cracked while driving. There were recalls on the Ford with the same engine. No injuries.

- Athens, AL, USA

Plastic intake manifold has separated from the vehicle while driving 40 mph. Dealer and the manufacturer were notified. Feel free to provide any further information.

- Marietta, IL, USA

Intake manifold has a crack, causing coolant to leak and engine to overheat. Dealer stated that some 1997 and 1998 were models were recalled; however this vehicle did not fall under recall due to VIN.

- Lake Palingo, MO, USA

The vehicles intake manifold developed a 4 1/2 inch crack at the front edge. This crack caused a total loss of all coolant.

- Miami, FL, USA

While driving, smoke began to come from under the hood, vehicle was taken in to a mechanic and consumer was infomred that the intake manifold had cracked.

- Lake Ronkonkoma, NY, USA