The composite (plastic) intake manifold may crack near the thermostat housing and cause a coolant leak. Ford released an updated manifold that was reinforced to prevent a recurrence. No recall was issued for this problem but Ford did extend the warranty to seven years on some models from the date of purchase.Google+
Car Problem Reports
Ford Crown Victoria Intake Manifold May Crack Leaking Coolant Behind the Alternator
Ford Crown Victoria Problem
Average Mileage: 122,959 mi (45,000 mi - 210,000 mi)
Visitor, 1999 Ford Crown Victoria, 120,000 mi
Coolant leak by the coolant crossover
on hard acceleration, the heater hose pops off the manifold. The radiator hose, when manually sqeazed, feels like there is no water pressure running through it.
Working on it
Trying copper stop leak
Visitor, 1997 Ford Crown Victoria, 85,000 mi
Cracked Intake manifold. Removed and replaced
Visitor, 1998 Ford Crown Victoria, 140,000 mi
Just had my car towed in do to this cracking on the interstate. Not a happy camper. Hope this is not to expensive.
Pol Int -- cracked intake manifold due to ford's bright idea to make money off of plastic intake manifold . Replaced myself with the help of the internet and youtube . Used part $55.00 (junkyard off internet) , gasket set $21.00(kragen/O'reilly), DEALER ONLY-new heater coolant return-line (under intake-manifold metal pipe)$45.00 (also due to fail soon after this manifold issue. BETTER to replace whilst everything is already off , no?)
New Dorman replacement is $200-250 for Manifold BUT includes gaskets built in .(Dealer is 234.00)
My cost in parts $121.00 with additional installation of Under Intake-Manifold Coolant Return Line .
Visitor, 1997 Ford Crown Victoria, 68,000 mi
Is being worked on.
Visitor, 1996 Ford Crown Victoria, 130,000 mi
Manifold cracked, OEM ones are plastic. Replaced with Aluminum one for 800 dollars.
Visitor, 1999 Ford Crown Victoria, 116,000 mi
Leak where plastic broke on manifold just below where thermastat goes.
Visitor, 2000 Ford Crown Victoria, 45,000 mi
coolant leak caused by crack in intake manifold. $1200 to replace and install. :-(