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.
Coolant Leak and/or Engine Overheating Due to Cracked Intake Manifold on Mercury Grand Marquis
Average mileage: 118,762 (10,700–308,000)
123 people reported this problem
82 people shared problem details
crack in the intake manifold...saw a recall on it for the plastic one to be replaced with the new aluminum, but my luck it does not apply to me because my car is to old. My mechanic is charging me 950 for the fix and said he would keep the information he found on line for this. I think Ford being a reputible company and Michigan based should step up and support all who have this problem no matter when it occurs
2000 Mercury Grand Marquis149,000Visitor
Heater box to intake manifold heater hose nipple stripped out at manifold. Lose about 1 gallon of antifreeze every 3 weeks. My mechanic says this is a common problem. Ford should be embarrassed and replace all for free. The engineer that designed the manifold and the manager that approved the design should own one of these cars for the rest of their lives.
2003 Mercury Grand Marquis129,000Visitor
Intake manifold cracked... gonna cost a bundle to replace. It would be nice if they weren't made out of plastic! Just doesn't make a whole lot of sence to me.
1998 Mercury Grand Marquis226,000Visitor
Plastic manifold cracked at the thermostat. No way to fix so no option but to replace. Dealer said it would cost $1,260 to replace (includes $400+ for the part). I bought the part on-line for $216 and did it myself. Took several hours but was not terribly difficult. Just a lot of stuff to take off, so mark hoses and wires well.
1996 Mercury Grand Marquis122,000Visitor
had my merc for awhile now and suddenly i smelled something and then saw smoke coming from under the hood, i pulled over and saw coolent everywhere took it in and found out i have a small crack behind my alternator on my intake manifold...did lots of research and come to find out im not the only one with this problem THANKS FORD.. for a new manifold online for $210 and now im going to attempt to replace it myself after finding out having a professional do what i can figure out will be 4 to 500 just for labor so wish me luck and again THANKS FORD!!
2003 Mercury Grand Marquis66,045Visitor
I purchased my Grand Marquis LSE new in 2003. As you can see from the mileage I do not drive the car a lot of miles per year. I maintain the car as required including replacing belts and hoses as required. The intake manifold developed a crack and had to be replaced. The cost was over $1000.It's a shame that an automobile that cost over $32000 at the time is manufactured with plastic parts that don't hold up. So much for Fords quality. I can see that I'm not the only one who has had this problem. One would think that Ford would stand behind their product. Although most of the reports that show this problem have a lot more miles on them than I do this part should not fail under normal driving conditions.
1997 Mercury Grand Marquis126,500Visitor
Pool of antifreeze on top of engine block beneath the induction manifold.
Just bought the car from an elderly gentleman who was the original owner. Looked and drove great untill I got it on the freeway and it went up in smoke... or should I say steam. Manifold cracked in the exact spot and cost me $1000 to fix. This will be my car for a long time, I hope.
1998 Mercury Grand MarquisVisitor
thermostat housing unit leaking
Parked in garage after a 45 miles drive. Found puddle of yellowish engine oil like fluid on floor. Car never overheat and no problem with transmission. Engine oil, power steering, brake and auto trans fluid all check out fine except coolant low and disappeared from overflow tank. Dealership identified the coolant leak caused by cracked intake manifold. Cost $1300 to replace.
1999 Mercury Grand Marquis151,000Visitor
2003 Mercury Grand Marquis109,000Visitor
leaking coolant made engine overheat...leak also caused a misfire on cyl 6
1997 Mercury Grand Marquis75,000Visitor
Cracked intake manifold.
1998 Mercury Grand Marquis87,650Visitor
Put a new intake manifold on
1999 Mercury Grand Marquis117,794Visitor
This 1999 Grand Marquis LS was purchased new; carefully run in the first 1,500 miles. One owner driven these miles and serviced regularly by authorized dealer only. Car does ot burn any engine oil - careful run in the first 1500 miles. Check oil, water regularly and began to notice overflow coolant tank needed topping up every two or 3 months. Car runs very smoothly till i found the puddle of yellowish fluid on the garage floor after a 45 min. drive. Soaked up fluid on paper and took it to Mercury dealership who determined the cracked manifold that needed to be replaced. Parts and labor totalled to $1300. I always request to save old parts to see how the parts wear or damaged. The new manifold was Made in China. (so are other Ford parts like Brake Rotors etc.) Said to be using thicker plastic, alum parts and should not crack too easily. However, i see GM's with 75,000 miles or less are having crack manifold problems. Personal Observation: The manifold is made of plastic composite wrapped over some alum. ducting or piping. Elementary physics taught us that plastic, composites, aluminium expands and contracts at different temperatures.... this design is so warped to have plastic wrapping over alum.in the intake manifold, is a buildt in disaster waiting to happen.... makes one wonder where these Mercury Ford engineers who designed the manifold came from??? Ford should be more responsible for their poorly designed products. blk.rat
1999 Mercury Grand Marquis98,000Visitor
plastic intake manifold cracked and leaking at temp sensor , have not fixed yet ,also coil pacs missfireing
2001 Mercury Grand Marquis70,000Visitor
Car leaks coolant fast, I think theres a hole in radiator , but now im not sure
This problem was found out because of a misfire in one cylinder when I was traveling. The mechanics just helped to clear out the fluid in the coil and hole so that I can get on the road. But they did give a report saying that the intake manifold appears to be leaking. They suggested to have a fully check after I got home.
1996 Mercury Grand Marquis75,000Visitor
If there wasn't a recall, WHY CAN'T WE MAKE A CLASS ACTION LAW SUIT???? a 2004 Grand Marquis with this problem.
I have heard alot of people saying there intake cracked on there grand marquis but on my 2000 m...
I have a coolant leak at a crack in the intake manifold at the top-front of the 4.2(maybe 4.6?)...
a crack manifold
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I saw two leaks on ground that look orange or rust. Went to a car mechanic and he said it is th...