Coolant Leak From Intake Manifold on Ford Thunderbird

Problem Description and Possible Solution

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.

Problem Data
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Average mileage: 95,942 (37,800–210,679)
Engines affected: 3.8L V6, 4.6L V8
2 model years affected: 1997, 2003
13 people reported this problem
Viewing 1 - 8 of 8 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
needed new intake manifold
Mechanic just found a crack in the manifold. Been having trouble with it running sluggish. :( Udenia Icenhour
Intake manifold was spraying coolant from a .5in hole
Thermostat housing crack led to coolant loss.
coolant leaking,had to install new manifold with alum. housing.
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