In the thread about the intake class action, I noticed a lot of people chipped in their sometimes conflicting experiences with the cracking manifold.
I hope with this thread we can actually figure out what Ford did in response to the problem initially, that way we can be armed with all of the information when settlement time comes around.
From the Ford Technical Service Bulletin 01M02: "A fatigue crack may develop in the composite intake manifold used on the 4.6L SOHC engine installed in your vehicle. This condition may result in engine coolant leakage, which, if not serviced, may cause engine overheating. Complete loss of coolant may result in engine damage or engine failure."
From everything I have seen, it looks as if the 01M02 recall only applied to the fleet vehicles, like Crown Vic Interceptors and Taxis. I have no idea if they replaced the manifold with the same plastic crack-tastic junk, or if they got the aluminum crossover manifold.
There is also this TSB & recall listed when I search www.tsb.com for my 97 bird: 97M91 MAR 99 - It is my general understanding that under this recall, Ford would replace a cracked manifold with another composite manifold. That's apparently what happened with my wife's 97 LX under the first owner. Her crossover cracked in '02 with 68k miles. We took it to the dealer and they said the intake was previously replaced under recall (with another plastic one), and was ineligible for further free repair. They wanted to charge us nearly $800 to repair it, and I don't recall if that was for the manifold with the aluminum crossover or not. We took the car to an independent mechanic who replaced it with the aluminum crossover manifold (listed as "F6SZ-9424-AA Kit" on the receipt).
Did anybody get their intake replaced for free with the aluminum piece? If so, what year is your car?
Did anybody get their intake replaced for free more than once? If so, did you eventually get the aluminum one?
If you did either get more than one replacement or get the aluminum piece for free, is it your impression that the dealer was doing you a favor / making a mistake, or did it seem like that was Ford policy?
Here's a letter I found online from Ford detailing that recall:
Ford Motor Company
P.O. Box 1904
Dearborn, Michigan 48121
97m91 April, 1999
Your Vehicle Identification Number: 12345678901234567
Mr. John Sample
123 Main Street
Anywhere, USA 12345
Ford Motor Company is providing a no-charge Service Program Number 97M91, to owners of certain 1996 through 1998 Crown Victoria Taxi, Town Car Limo Prep & Livery Package, 1996 and 1997 Thunderbird, Cougar and Mustang vehicles equipped with 4.6L SOHC engines. This service program provides additional coverage for the intake manifold.
REASON FOR THIS PROGRAM
Fatigue cracks may develop in some of the composite intake manifolds used on the 4.6L SOHC engines installed in the affected cars. This condition may result in engine coolant leakage which, if not detected or ignored, will cause engine overheating. Complete loss of coolant may result in engine damage or engine failure.
WHAT WE WILL DO
If the engine of your car should develop a coolant leak at the intake manifold cross over coolant passage, located directly behind the alternator, your dealer will verify the condition. If the coolant leakage is from the location described above, your dealer will replace the engine intake manifold assembly free of charge.
This no charge coverage is available for 7 years from the vehicle's warranty start date (no mileage limitation) and is automatically transferred to subsequent owners.
WHAT YOU SHOULD DO
PLEASE KEEP THIS LETTER. If your car's engine intake manifold should exhibit the above condition within the 7 year coverage described above, contact your dealer. Show the dealer this letter. The dealer will replace the intake manifold assembly after verification of this specific condition. If you should lose this letter the dealer will still honor the provisions of this program.
REFUNDS
If you paid to have the engine intake manifold replaced due to a leak at the cross over coolant passage before the date of this letter, Ford is offering a full refund. For the refund, please give your paid original receipt to your Ford or Lincoln Mercury dealer. To avoid delays, do not send receipts to Ford Motor Company.
CHANGED ADDRESS OR SOLD THE VEHICLE?
Please fill out the enclosed prepaid postcard and mail it to us if you have changed your address or sold the vehicle.
We are taking this action as part of our ongoing efforts to maintain owner confidence in our products. We hope this program will confirm your continued satisfaction in your Ford-built vehicle.
--------------------------------------------------------------------------------
CPR © 1999 FORD MOTOR COMPANY
Published By: Recall/Service Programs Department
I hope with this thread we can actually figure out what Ford did in response to the problem initially, that way we can be armed with all of the information when settlement time comes around.
From the Ford Technical Service Bulletin 01M02: "A fatigue crack may develop in the composite intake manifold used on the 4.6L SOHC engine installed in your vehicle. This condition may result in engine coolant leakage, which, if not serviced, may cause engine overheating. Complete loss of coolant may result in engine damage or engine failure."
From everything I have seen, it looks as if the 01M02 recall only applied to the fleet vehicles, like Crown Vic Interceptors and Taxis. I have no idea if they replaced the manifold with the same plastic crack-tastic junk, or if they got the aluminum crossover manifold.
There is also this TSB & recall listed when I search www.tsb.com for my 97 bird: 97M91 MAR 99 - It is my general understanding that under this recall, Ford would replace a cracked manifold with another composite manifold. That's apparently what happened with my wife's 97 LX under the first owner. Her crossover cracked in '02 with 68k miles. We took it to the dealer and they said the intake was previously replaced under recall (with another plastic one), and was ineligible for further free repair. They wanted to charge us nearly $800 to repair it, and I don't recall if that was for the manifold with the aluminum crossover or not. We took the car to an independent mechanic who replaced it with the aluminum crossover manifold (listed as "F6SZ-9424-AA Kit" on the receipt).
Did anybody get their intake replaced for free with the aluminum piece? If so, what year is your car?
Did anybody get their intake replaced for free more than once? If so, did you eventually get the aluminum one?
If you did either get more than one replacement or get the aluminum piece for free, is it your impression that the dealer was doing you a favor / making a mistake, or did it seem like that was Ford policy?
Here's a letter I found online from Ford detailing that recall:
Ford Motor Company
P.O. Box 1904
Dearborn, Michigan 48121
97m91 April, 1999
Your Vehicle Identification Number: 12345678901234567
Mr. John Sample
123 Main Street
Anywhere, USA 12345
Ford Motor Company is providing a no-charge Service Program Number 97M91, to owners of certain 1996 through 1998 Crown Victoria Taxi, Town Car Limo Prep & Livery Package, 1996 and 1997 Thunderbird, Cougar and Mustang vehicles equipped with 4.6L SOHC engines. This service program provides additional coverage for the intake manifold.
REASON FOR THIS PROGRAM
Fatigue cracks may develop in some of the composite intake manifolds used on the 4.6L SOHC engines installed in the affected cars. This condition may result in engine coolant leakage which, if not detected or ignored, will cause engine overheating. Complete loss of coolant may result in engine damage or engine failure.
WHAT WE WILL DO
If the engine of your car should develop a coolant leak at the intake manifold cross over coolant passage, located directly behind the alternator, your dealer will verify the condition. If the coolant leakage is from the location described above, your dealer will replace the engine intake manifold assembly free of charge.
This no charge coverage is available for 7 years from the vehicle's warranty start date (no mileage limitation) and is automatically transferred to subsequent owners.
WHAT YOU SHOULD DO
PLEASE KEEP THIS LETTER. If your car's engine intake manifold should exhibit the above condition within the 7 year coverage described above, contact your dealer. Show the dealer this letter. The dealer will replace the intake manifold assembly after verification of this specific condition. If you should lose this letter the dealer will still honor the provisions of this program.
REFUNDS
If you paid to have the engine intake manifold replaced due to a leak at the cross over coolant passage before the date of this letter, Ford is offering a full refund. For the refund, please give your paid original receipt to your Ford or Lincoln Mercury dealer. To avoid delays, do not send receipts to Ford Motor Company.
CHANGED ADDRESS OR SOLD THE VEHICLE?
Please fill out the enclosed prepaid postcard and mail it to us if you have changed your address or sold the vehicle.
We are taking this action as part of our ongoing efforts to maintain owner confidence in our products. We hope this program will confirm your continued satisfaction in your Ford-built vehicle.
--------------------------------------------------------------------------------
CPR © 1999 FORD MOTOR COMPANY
Published By: Recall/Service Programs Department
