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Old 04-13-2009, 20:53   #1 (permalink)
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4.6 coolant leak

1996 4.6

I've got some coolant leaking near the T-stat housing
and also small amount gathering at the #2 injector
(forward most passenger side)

this an intake issue or something more simple?
would greatly appreciate help
thanks in advance,,,,, Joe
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Old 04-17-2009, 08:51   #2 (permalink)
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Re: 4.6 coolant leak

is your lower intake the recalled plastic type or the aluminum crossover? i know Ford had service issues with the plastic type lower intakes cracking and were replacing them with aluminum due to failure
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Old 04-17-2009, 16:21   #3 (permalink)
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Re: 4.6 coolant leak

Hi
thanks for the reply
it's all black plastic

So do I look for a new intake or is it just a crossover or something
that I have to replace?
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Old 04-17-2009, 21:39   #4 (permalink)
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Re: 4.6 coolant leak

the plastic intakes crack and were recalled... at least for the Crown Victoria, Grand Marquis and Town Car and were replaced with aluminum... i would contact Ford about it and ask about the 4.6L lower plastic intake recall...
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Old 04-18-2009, 06:27   #5 (permalink)
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Re: 4.6 coolant leak

OK do I call a local dealer or is there an 800 number or something
that I call ?

Thanks for all the help, much appreciated
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Old 04-18-2009, 22:54   #6 (permalink)
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Re: 4.6 coolant leak

Ford Motor Company will extend the recall (01M02) on 4.6L V8 equipped vehicles with plastic intake manifolds. Some of the composite intake manifolds used on 4.6L SOHC engines may develop fatigue cracks at the coolant crossover duct. This condition could result in engine coolant leakage which, if not serviced, may cause engine overheating. Complete loss of coolant may result in engine damage or engine failure.

QUESTIONS?
Claims Information: 1-800-423-8851

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Other (Dealer Only) Recall Questions: 1-800-325-5621

P.O. Box 1904

Dearborn, Michigan 48121

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Old 04-18-2009, 22:56   #7 (permalink)
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Re: 4.6 coolant leak

TO: All Ford and Lincoln Mercury Dealers

SUBJECT: Owner Notification Programs 97M91 and 01M02: PARTS UPDATE

References:

Owner Notification Program 01M02: Additional Coverage on Certain 4.6L SOHC Intake Manifolds Installed on certain 1996-2001 Crown Victoria Taxis, Police cars and Lincoln Town Car Limousine and Livery cars

Owner Notification Program 97M91: Certain 1996-1998 Crown Victoria Taxis, Town Car Limo Prep & Livery Packages, 1996-1997 Thunderbird, Cougar and Mustang Vehicles Equipped With 4.6L SOHC Engines- Intake Manifold Additional Coverage

The intake manifolds specified in the subject programs have been obsoleted. Please consult the chart below to determine part requirements



MODEL YEAR
MODELS
OLD INTAKE MANIFOLD PART #
NEW INTAKE MANIFOLD

1996 - 1997
1996 - 1998
Thunderbird, Cougar
Mustang
F8AZ-9424-BC*
F6SZ-9424-AA

1999 - 2001
Mustang
1L2Z-9424-DA*
1R3Z-9424-AAA

1996 - 1997
Crown Victoria, Grand Marquis, Town Car - All
F8AZ-9424-BC*
F8AZ-9424-AAA

1998 - 2000
Crown Victoria, Grand Marquis, Town Car: Police, Limosine Vehicles
F8AZ-9424-BC*
F8AZ-9424-CA

1998 - 2000
Crown Victoria, Grand Marquis, Town Car: Retail Vehicles
F8AZ-9424-BC*
F8AZ-9424-BAA

2001
Crown Victoria, Grand Marquis, Town Car: Police, Limosine Vehicles
1L2Z-9424-DA*
1W7Z-9424-BA

2001
Crown Victoria, Grand Marquis, Town Car: Retail vehicles
1L2Z-9424-DA*
1W7Z-9424-AAA



* indicates the Obsolete Intake Manifold - DO NOT ORDER
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Old 04-18-2009, 23:02   #8 (permalink)
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Re: 4.6 coolant leak

mustang story about intake... dont get bullied by the dealer.......

The intake manifold in my '96 Mustang cracked while the dealer was performing routine maintenance - they covered it under recall. 100 Miles later, the engine "blew". The dealer found a stuck valve in #5 and told me that I had to either pay them $3250 for new heads or $5000 for a new engine! After consulting with some knowledgeable friends, I confronted the dealer and had them admit that I didn't need new heads or engine AND that they needed to check to see if debris from the failure & replacement of the manifold caused the engine failure. They pulled the head and found debris and I am getting a new head for free. I have read other sites where the manifold failure has lead to other engine problems - be careful AND don't let the dealer bully you into bogus repairs!
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Old 04-24-2009, 23:36   #9 (permalink)
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Re: 4.6 coolant leak

Hey thanks appreciate all your help
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Old 05-08-2009, 06:00   #10 (permalink)
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Re: 4.6 coolant leak

Hate to sound dumber than a rock, but what is the proper test to determine what is causing this type of leak? I have anitfreeze appearing at the base of the black plastic below the thermostat housing, that runs along the top of the valve cover and down to the ground at the back of the engine.

Is it even possible that Ford will replace such a thing on a '96 model?

thanks!
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