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.
Problems for specific Ford Crown Victoria years:
Car problem reports
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Most reported Ford Crown Victoria problems
Certain police, fleet, and natural gas models may experience lower ball joint wear, requiring replacement of the front ball joints. Ford has issued a recall on certain vehicles for this condition. Please contact your local dealer for more information.
The throttle position sensor (TPS) may fail. Common symptoms of a defective TPS can be rough idle, hard starting, hesitation on acceleration, poor fuel economy, and stalling.
The engine may overheat at idle when the AC is on. A new, upgraded fan motor and resistor assembly should be installed.
A spring in the seat belt buckle may wear or fail, causing the airbag light on the instrument panel to illuminate. Failed buckles will require replacement.
The battery light may illuminate on the instrument panel because the alternator wire harness connector is damaged. A new connector kit is available and should be installed to correct this concern.
Catalytic converter failure is common. Internal components become loose, causing a rattle or creating back pressure in the exhaust.
If you experience difficulty starting the engine when cold, stalling at idle, or hesitations during acceleration, it may be the idle air bypass valve. This valve helps the vehicle idle steady when the accelerator pedal is not pressed.
Exhaust manifold gaskets need to be replaced around 100,000 give or take. They just go on these cars, more on passenger side-