Ford Crown Victoria intake manifold crack causing leak at thermostat, requires replacement on Ford Crown Victoria

Some Ford Crown Victoria owners report experiencing coolant leaks around the thermostat housing where it meets the intake manifold, often at the seam between these two components. These leaks may be caused by a damaged gasket or seal, which is a common issue. Additionally, some owners have noted that composite intake manifolds used in 4.6L SOHC engines can develop fatigue cracks at the coolant crossover duct, leading to coolant leakage and potential engine overheating. Over time, the intake manifold can also age and crack, contributing to leaks in the thermostat area. Furthermore, if the thermostat support has receded into the housing, it may fail to provide a proper seal, resulting in leaks. To mitigate these issues, it is recommended that owners inspect the gasket and intake manifold for damage, and consider replacement if necessary, while consulting a qualified mechanic for proper diagnosis and repair.