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 From Intake Manifold on Ford Thunderbird
Average mileage: 91,059 (37,800–210,679)
Engines affected: 3.8L V6, 4.6L V8
11 people reported this problem
6 people shared problem details
This is 2nd time I've had to repair this problem with coolant leaking;( Cheap plastic container... shame on Ford!! Ford should pick up the bill for faulty and inexcusable problem
2003 Ford Thunderbird75,000Visitor
needed new intake manifold
2003 Ford Thunderbird- 3.8L V664,000Visitor
Thermostat housing crack led to coolant loss.
1997 Ford Thunderbird- 4.6L V850,000Visitor
coolant leaking,had to install new manifold with alum. housing.
1997 Ford Thunderbird- 4.6L V876,000Visitor
The composite (plastic) intake manifolds could crack near the thermostat housing and cause a coolant leak. Ford released an updated manifold that was reinforced to prevent a recurrence. I purchased an after-market intake manifold that was much cheaper and owrks fine
intake manifold cracked at thermostat. Ford had recall on manifold. replaced with same manifold. happened again. 2nd time replaced with different manifold. alu.for front crossover, composite the rest. Dealer replaced no cost
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