Check for coolant leak at intake manifold. Replaced intake manifold. There were regular oil changes and tire rotation. The engine light had come on, and the coolant light would come on and off. The dealer had to replace the engine sensor light and added a cup of water. The consumer's son in law was driving the vehicle and white smoke coming from under the vehicle, the rubber strip on the inside of the vehicle was coming off, the right rear trim panel coming loose, the brakes made rubbing noise intermittently, glove box door won't shut, the air bag would rattle, the right front door rattled while the vehicle was in motion, and the door switch trim panel was discolored.

- Lubbock, TX, USA

Intake manifold has developed a crack. As a result, water leaked out, and the engine overheated.

- Broadway, NC, USA

Intake manifold cracked. Made of a plastic material. Is there any recalls out there for this" if not, why not? why would you put plastic material in the engine"

- O Fallon, IL, USA

Intake manifold is made of plastic. There was a failure in the plastic material on the water cross-over jacket (portion of the manifold). This caused all the coolant to flood out. I found Ford had issued a tsb (97M91) throgh its owners notification program (onp) identifying fatigue and failure of this part. A new part had been designed by Ford engineers that used an aluminum coolant cross-over jacket rather than the plastic. The onp tsb was released in 1999. I called the support phone number, 1-800-392-3673. Is now the claims number. However, he indicated the VIN number still showed the previous owner. This was promptly changed. It turns out the 7 year extended warranty issued by Ford (to all new and subsequent owners) had expired in may of this year. Hear is my problem: 1. I bought the car(used) from a major dealer in March of 2002. Why did Ford not have my owners information" what good is the onp if it is inaccurate? 2. I had to do an extensive search to find this tsb 97M91. Had I known about this, I would of had it replaced before it failed, or had it periodically inspected.. I was never given the opportunity to make that descision. 3. it seems the owners notification program only benefits those who are "in the computer system". 4. I feel I have no recourse to negotiate with Ford. The claims phone number offered no assistance to this inquiry. 5. this is a poorly designed part. So poor, Ford issed a 7 year extended warranty. What makes them feel they have no obligation to its consumers even after 7 years? this is a major system component. It should have a reasonable life expectancy. It would not be considered acceptable to crack an engine block, head, transmission bellhousing. So why is it accepted that 7 years is acceptable for an intake manifold" it is not normal to have a 3 inch fatigue crack in an intake manifold. I feel Ford should include my vehicle in a mandatory recall of this part.

- Beaverton, OR, USA

Intake manifold is made of a composite material the heat of motor must have cracked it, the crack is right behind where the alternator sits. So, it is on the front of the intake. Why is an intake made of plastic anyway?

- Chickamauga, GA, USA