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.
Average mileage: 110,315 (50,000–194,000)
Engines affected: 3.8L V6, 4.6L V8
10 people reported this problem
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.
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.
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