Intake Manifold Cracked


really awful
Typical Repair Cost:
Average Mileage:
97,000 miles
Total Complaints:
1 complaints

Most Common Solutions:

  1. replace intake manifold (1 reports)
1996 Mercury Cougar engine problems

engine problem

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1996 Mercury Cougar Owner Comments

problem #1

Jul 202007

Cougar XR7 4.6L

  • Automatic transmission
  • 97,000 miles


1996 mercury cougar with 4.6L V8. We bought it brand new and have take well care of it. While traveling in remote Montana the intake manifold cracked just behind the alternator and water (antifreeze) poured out of the crack onto the engine block. I had to have it towed 98 miles to my nephew who was the closest mechanic. Found out that Ford had a recall on these intake manifolds but they don't tell owners of the problems just the ford shops. The problem is the intake manifold is plastic and Ford mounted the alternator on the manifold. When the engine is accelerating the intake manifold will crack where the alternator is attached to it. This allows antifreeze water to pour out on to the engine block. The engine will eventually overheat if driven much farther.

I purchased a new manifold from Ford dealer in Spokane WA and drove back to car. My nephew and I replaced the manifold in one day. The new manifold was braced with a metal bracket where the alternator connects to it. Ford did not warrant. If Ford would have just told me about problem I probably would have it taken care of before I was in some remote Montana road. Dissapointed in Ford Motor Co for not helping at all in alerting me or helping to get the car back on the road.

- Robert R., Tacoma, WA, US

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