Hey guys, I've been reading a long time, but had to get on for real and get some help. I had a crack in my intake on my 99 GT and Ford won't pay so I'm doing it myself. I've got the old one off and am preparing to put the new one on. I'm looking for any advice to make sure I do this right. Any help or advice you guys have would be appreciated. Thanks.

 

put the new one on just liike you took the old one off. DO NOT FORGET to burp the cooling system or you'll overheat. keep everything VERY clean and take pictures the whole time so you can reference where things go in case you forget. Sticky labels are also a good idea.

 

I remember somewhere they took that to trial and won making Ford pay for the intake swap, if cracked, and paying back people that they refused to fix, that had to pay. There is a TSB on those intakes that don't have the aluminum cross over, which is why they did that, to prevent more intakes from cracking. I would ask around about that. i've read so much shady stuff Ford will do just to get away from fixing their F**k ups.

 

Section 2: Cracking Plastic Intake Manifolds on Ford V-8 Engines
Section created 11-14-03**, updated 3-17-06
In the 'good old days' intake manifolds were made from cast iron or aluminum. When Ford's new plastic manifolds crack next to the thermostat housing, you lose your coolant, with the potential to seize your motor.

Vehicles possibly affected: 1996 through 2002, with 4.6 litre V-8.
Let us know about cracking manifolds with coolant leaks in other, or later, models.

The "Settlement"

In a December 2005 "settlement" of a class-action lawsuit, Ford agreed to compensate many owners for the cracked manifolds.

 

Cracking Plastic Intake Manifolds on Ford V-8 Engines
The December 2005 "Settlement"
This page created on 6-25-05, updated 3-17-06

Summary:

Ford was sued about their cracking plastic manifolds, lost, and then settled. The "settlement" received final court approval on December 16, 2005.

The settlement provided a very short period of time for submission of claims - the deadline was March 16, 2006.

The settlement also excluded many vehicles.

If you were excluded, or heard about the settlement too late to file, please contact the editor of this website.

http://www.flamingfords.info/manifoldSettlement.html


Well if you still have to replace it your self, make sure you do what r3dn3ck wrote, it will help alot. also i think a few months to fix intakes by ford is BS, should be anytime, even if it's 10 years from now, they made the junk, they should fix it.

 

Just want to thank you guys for the help. One thing I'm not too sure about is the gaskets between the intake and block. The new intake comes with the gaskets built into the intake so a mech. at my local ford dealer says I don't need the spacer style gasket. I'll keep checking in and eventually give you guys all the details on my baby w/some pics. Thanks again. I did take pics by the way.

 

I got my money back from Ford for replacement. Its not too difficult but you do need a torque wrench and basic tools. The intake I have now is o ringed so you dont need any gaskets. Make sure you cover up the holes when cleaning as you dont want dirt getting into the cylinders. Its not difficult but you do have to remove alot of stuff. I would say its a do it yourself if you have basic knowledge of cars and have wrenched before as its just removing parts and putting them back in.

 

how did u go about gettin your money back? i have a 96 and i went through this whole thing with the cracked manifold and i ended up replacing the manifold with the 99-04 pi manifold (did it myself) and as far as i could tell there was no way to get my money back unless my car was 99 or newer? this would be awsome if i can get some money back lol

 

TSB 02-2-2
Publication Date: JANUARY 17, 2002

Coolant
Coolant seepage at intake manifold cross-over - Vehicles equipped with 4.6L 2V Engine Only
Engine
4.6L 2V - Coolant Seepage at Intake Manifold Cross-Over


FORD: 1996-97 THUNDERBIRD
1996-2001 CROWN VICTORIA, MUSTANG
2002 EXPLORER
LINCOLN: 1996-2001 TOWN CAR
MERCURY: 1996-97 COUGAR
1996-2001 GRAND MARQUIS


ISSUE:
Some vehicles may exhibit an Intake Manifold crossover (first runner) coolant seepage condition. This may be caused by a crack in the Intake Manifold coolant crossover.

 

96 and 97 qualitfied for the free replacement but 98,99,01 did not and this caused the lawsuit, why not included all years. Im not sure what you can do to get your money as you could of just gotten taken care of at Ford as your year to my knowledge was covered.

 

I read another forum about someone with an 05 GT had UDP's on their car and the check engine came on and it was a bad Alternator. He took it to the dealership, that he didn't buy his car from, they said he had UDP's and it voided the warranty on the alt and won't replace it. He then told the guy there's a TSB on bad alt's on the 05's and the magnuss something,talking about that dealers can't say it voids the warranty unless they can prove the aftermarket part worked and federal law, the ford guy laughed and said no. anyways after a long battle the ford guy said he would do it but if ford moco didn't pay that dealership back, they would send him the bill.
Another guy wrote in saying his daughter worked at Ford MoCo and the reason is, if the dealership replaces it, they send it to Ford MoCo and they might give the dealership money for the work and sometimes they don't, even if there is a TSB, that's why some dealerships won't touch some cars. I think Ford MoCo needs to worry about the customers, not their own pockets....