Car Problem Reports

Mercury Cougar Plastic Intake Manifold May Crack Causing Coolant Leak

Mercury Cougar Problem
8 Reports
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Model Year Affected: 1997

Engines Affected: 3.8L V6, 4.6L V8

Average Mileage: 110,315 mi (50,000 mi - 194,000 mi)


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.

  • Visitor, , 4.6L V8, 50,000 mi

    Didn't know about the class action lawsuit or anything. I never had any external antifreeze leaks, but a recurrent leak of some sort developed on the floor of the passenger side. Low coolant indicator light came on every couple of months, so I added more accordingly. Took to a mechanic when a rattling sound developed under the hood, and was told I needed to get rid of the car, due to cracked plastic manifold gasket. Barely made it to a lot to trade it in, and antifreeze leaked out all over their pavement.

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  • Visitor, , 4.6L V8, 194,000 mi

    Just found out today that my 97' Mercury Cougar has a cracked intake. Will cost between $500-$600 to fix and has a bad oil leak also. Pretty expensive for an old car with a lot of miles. But then again it went 194,000 miles before it did it so maybe that's a good thing. Still there really should have been a recall on something that's plastic. Still a nice ride so I'm sure I will have it fixed.

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  • Visitor, , 4.6L V8, 108,000 mi

    Ridiculously hard to find a used one! New was a special order and over $300

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  • Visitor, , 3.8L V6

    1997 Mercury Cougar - replaced thermostat still overheating - leaking anti-freeze but not sure where

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  • Visitor, , 3.8L V6, 56,000 mi

    blown head gasket

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  • engine overheated, took to shop and when tech pressure tested system, it was leaking around the heater hose area where it comes out of the minifold

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