Coolant Leak From Intake Manifold on Lincoln Town Car

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.

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Average mileage: 134,035 (175–320,000)
Engine affected: 3.8L V6
12 model years affected: 1993, 1996, 1997, 1998, more1999, 2000, 2001, 2002, 2003, 2004, 2005, 2007
88 people reported this problem
59 people shared problem details
1998 Lincoln Town Car130,000
composite plastic intake manifold has crack near thermostat housing can you replace just that part or the whole housing how much
2001 Lincoln Town Car163,000
car overheats changed water pump, thermostat, check heater core, front passenger seat floor wet help
Crack found on inner thermostat housing, leaking coolant.
1999 Lincoln Town Car115,788
the neck cracked bc it got to hot and the neck is just plastic so have to get a new one that wasnt plastic and it works great
leak near thermostat housing
1999 Lincoln Town Car124,321
Thermostat housing leaking coolant. Manifold cracked in two places - front and rear of manifold. Manifold was replaced. Total bill, including labor was: $839.32
Engine missing, SES came on. Turned it in @ dealership for servicing. Cracked manifold replaced, coolant evacuated from cylinders, and new plugs/plug wires.
had to replace severely cracked manifold
2005 Lincoln Town Car104,000
Antifreeze leak from intake manifiold. Removed parts above it and found one large crack in intake manifild that was original equipment.It came from factory made out of a hard plastic.Replace with a upgraded intake manifold(after market) with some aluminum parts to it. After all said and done the leaks have stopped and the system is working properly again.Cost of parts and labor 600.00.
1999 Lincoln Town Car177,000
Car left me stranded in Gatlinburg , TN. while on vacation. Costs me $1,400.00 to fix at dealer. Ford's recall had run out.
2004 Lincoln Town Car111,183
Engine light comes on with heat light showing
2001 Lincoln Town Car176,000
I need my coolant thermostat replaced but am afraid that the intake manifold may crack causing a major repair cost. The problem with not repairing it is the engine rpm fluctuates because the cars computer is trying to adjust rpm to engine temperature. Is not replacing the thermostat going to cause further problems?
2004 Lincoln Town Car190,000
Intake manifold was broken out around the bottom side of the thermostat housing. The manifold was changed and the problem was fixed.
2002 Lincoln Town Car130,000
it leak by thermostat housing
2004 Lincoln Town Car169,000
leaking antifreeze upon inspection found large crack on plastic manifold. I have no idea why or what jackass at Ford made the decision to use plastic on such a important and hard to replace part. I also don't understand how nobody has designed a METAL replacement so i had to replace with another one made out of plastic that cost $250 with a new set of seals at $50 took about 6hrs not recommended for DIY better to pay labor at a shop if not a lot experience. Way to go Ford makes me feel so much safer knowing almost all POLICE INTERCEPTORS will have the same problem before the are put out of service. Sad truth is they didn't learn a damn thing after this and to this day insist on making plastic parts on engines to save weight and money instead of making sure they are making a DEPENDABLE engine.
2003 Lincoln Town Car200,000
I installed a new intake now its leaking on passenger side is something wrong with gasket
2003 Lincoln Town Car140,000
intake manifold leaking between manifold and crossover pipe , I saw that some of these intake manifolds were part of Fords problem , is this under warranty ?
Small coolant loss at first. Later, when engine rpm are increased, coolant blows out big time, appearing to come from the area behind the alternator up toward the fan. Drive-ability is not feasible until repaired. I'm still weighing my options, a year or more later. This makes me very disappointed and displeased with the quality of this important part, on a so called "luxury car". Come on Ford/Lincoln/whomever, you can do better than this, if nothing else, stay with the tried and true metals of years ago.
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