Tap a category to read its complaints. One report may name several components.
When problems were reported
Mileage at the reported incident
Limited mileage data: 36 of 233 reports include usable mileage. There isn’t enough coverage to show a useful chart.
NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.
What to inspect
Issues worth paying extra attention to based on owner reports.
Engine And Engine Cooling. Review the 65 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
Service Brakes, Hydraulic. Review the 46 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
Power Train. Review the 21 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
NHTSA owner reports · September 18, 2026 snapshot.
12 crash reports4 fire reports9 injury reports
What owners actually said
233 reports
Mileage unknown · Apr 11, 2006
Electrical SystemEngine And Engine CoolingLatches/locks/linkages
COMPLIANT IS THAT THROUGH MY INSURANCE PROVIDER I WAS ALERTED TO TWO RECALLS THAT SHOULD BE AT LEAST LOOKED INTO ON MY AUTO. THE FIRST IS THE BLOWER ON THE CLIMATE CONTROL BEGAN TO WORK ERRATICALLY AND NOW IT DOES NOT WORK AT ALL. MEANING THAT MY DEFROSTING DOES NOT WORK AT ALL. THE OTHER AND MORE SERIOUS IS THAT THE DRIVERS …
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COMPLIANT IS THAT THROUGH MY INSURANCE PROVIDER I WAS ALERTED TO TWO RECALLS THAT SHOULD BE AT LEAST LOOKED INTO ON MY AUTO. THE FIRST IS THE BLOWER ON THE CLIMATE CONTROL BEGAN TO WORK ERRATICALLY AND NOW IT DOES NOT WORK AT ALL. MEANING THAT MY DEFROSTING DOES NOT WORK AT ALL. THE OTHER AND MORE SERIOUS IS THAT THE DRIVERS SIDE DOOR LATCH STICKS AT SMACKS AGAINST THE PEG AND DOES NOT LATCH PROPERLY OR AT ALL, UNLESS THE LATCH IS MANUALLY LIFTED. BOTH OF THESE ARE RECALLS FOR OTHER T-BIRDS BUT SOMEHOW MINE SLIPPED THROUGH. VIN IS [XXX]. IF THESE ARE SUCH COMMON PROBLEMS WHY WEREN'T ALL THE T-BIRDS RECALLED? I AM LOOKING AT OVER 600.00 TO REPLACE THESE PARTS. WHICH IS IRRITATING WHEN FORD SHOULD BE FIXING IT'S KNOWN PROBLEMS. *NM UPDATED 07/16/2012 * JS INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
NHTSA ODI #10155041
127,000 miles · Jan 20, 2006
Engine And Engine Cooling
DT*: THE CONTACT STATED THE INTAKE MANIFOLD CRACKED AND CAUSED THE VEHICLE TO OVERHEAT WITHOUT PRIOR WARNING. THE VEHICLE WAS SEEN BY AN INDEPENDENT REPAIR SHOP. THE REPAIR SHOP PERSONNEL SUGGESTED THE MANIFOLD CRACKED DUE TO THE COMPOSITE PLASTIC USED IN MANUFACTURING. THE MANIFOLD WAS REPLACED WITH AN AFTER MARKET MANIFOLD …
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DT*: THE CONTACT STATED THE INTAKE MANIFOLD CRACKED AND CAUSED THE VEHICLE TO OVERHEAT WITHOUT PRIOR WARNING. THE VEHICLE WAS SEEN BY AN INDEPENDENT REPAIR SHOP. THE REPAIR SHOP PERSONNEL SUGGESTED THE MANIFOLD CRACKED DUE TO THE COMPOSITE PLASTIC USED IN MANUFACTURING. THE MANIFOLD WAS REPLACED WITH AN AFTER MARKET MANIFOLD MADE OF METAL MATERIAL. *NM
NHTSA ODI #10148186
Mileage unknown · Dec 22, 2005
Engine And Engine Cooling
I HAD A 96 T-BIRD THAT MY DAUGHTER NOW OWNS. THE PLASTIC MANIFOLD CRACKED LAST SPRING CAUSING ME TO BE STRANDED ON THE HIGHWAY. MY SISTER TOWED ME TO HER HOUSE WHERE THE VEHICLE SAT UNTIL I GOT A NEW MANIFOLD FOR ABOUT $289 ONLINE. I INSTALLED IT MYSELF TAKING ME ABOUT 2 DAYS AND DRIVING 45 MILES EACH WAY TWICE TO MY SISTER'S…
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I HAD A 96 T-BIRD THAT MY DAUGHTER NOW OWNS. THE PLASTIC MANIFOLD CRACKED LAST SPRING CAUSING ME TO BE STRANDED ON THE HIGHWAY. MY SISTER TOWED ME TO HER HOUSE WHERE THE VEHICLE SAT UNTIL I GOT A NEW MANIFOLD FOR ABOUT $289 ONLINE. I INSTALLED IT MYSELF TAKING ME ABOUT 2 DAYS AND DRIVING 45 MILES EACH WAY TWICE TO MY SISTER'S HOUSE. OLD PART WAS DISCARDED. *NM
NHTSA ODI #10145883
78,652 miles · Oct 3, 2005
Engine And Engine Cooling
INTAKE MANIFOLD CRACKED. THIS PART WAS MADE OUT OF NYLON AND IS A KNOWN DEFECTIVE PART INSTALLED AT THE FACTORY. FORD MOTOR COMPANY REFUSED TO REIMBURSE STATING THAT THERE WAS A CUSTOMER SATISFACTION ACTION IN 1996. SINCE THE PROBLEM WAS DUE TO A KNOWN DEFECTIVEPART I THINK IT SHOULD BE COVERED FOR LIFE OF THE VEHICLE. LATER…
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INTAKE MANIFOLD CRACKED. THIS PART WAS MADE OUT OF NYLON AND IS A KNOWN DEFECTIVE PART INSTALLED AT THE FACTORY. FORD MOTOR COMPANY REFUSED TO REIMBURSE STATING THAT THERE WAS A CUSTOMER SATISFACTION ACTION IN 1996. SINCE THE PROBLEM WAS DUE TO A KNOWN DEFECTIVEPART I THINK IT SHOULD BE COVERED FOR LIFE OF THE VEHICLE. LATER FORD REDISIGNED THE PART USING ALUMINUM INSTEAD OF NYLON. *NM
NHTSA ODI #10138329
60,000 miles · Jul 26, 2005
Engine And Engine Cooling
3.8 CYLINDER HEAD FAILURE
NHTSA ODI #10130144
Mileage unknown · Jul 8, 2005
Latches/locks/linkages
DT: THE DRIVER'S SIDE DOOR OPEN'S PROPERLY BUT DOES NOT CLOSE AS IT SHOULD. THE CONSUMER THINKS THE DOOR IS CLOSED CLOSE UNTIL NOTICING THAT THE DOOR AJAR LIGHT IS ILLUMINATED ON THE INSTRUMENT PANEL. *AK *NM
NHTSA ODI #10123834
81,335 miles · Apr 21, 2005
Engine And Engine CoolingFire
PLASTIC INTAKE MANIFOLD FAILURE ON A 1996 FORD THUNDERBIRD V8. PART FAILURE WAS PRECEDED BY A "CHECK ENGINE LIGHT" AND "LOW COOLANT" LIGHT. TURNS OUT THAT FORD HAD PUT OUT "SERVICE BULLETIN" IN 1999 AND FOLLOWED UP ON IT IN 2001 ON THIS ISSUE (97M91) YET THEY NEVER NOTIFIED ANY OWNERS. COST OF REPAIRS FOR THIS PART WILL BE…
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PLASTIC INTAKE MANIFOLD FAILURE ON A 1996 FORD THUNDERBIRD V8. PART FAILURE WAS PRECEDED BY A "CHECK ENGINE LIGHT" AND "LOW COOLANT" LIGHT. TURNS OUT THAT FORD HAD PUT OUT "SERVICE BULLETIN" IN 1999 AND FOLLOWED UP ON IT IN 2001 ON THIS ISSUE (97M91) YET THEY NEVER NOTIFIED ANY OWNERS. COST OF REPAIRS FOR THIS PART WILL BE AROUND $1,000 YET FORD WILL NOT DO ANYTHING WILLINGLY TO RECTIFY THE SITUATION. FAILURE OF PART COULD LEAD TO CATASTROPHIC ENGINE FAILURE IF NOT CORRECTED. *MN
NHTSA ODI #10118241
Mileage unknown · Feb 17, 2005
Visibility
THE DRIVER NOTICED THAT THE BLOWER WAS INOPERATIVE. THE BLOWER FAILS TO TURN ON SOMETIMES AND IT STICKS ON HIGH AT ALL TIMES. THE VEHICLE WAS TAKEN TO THE DEALER FOR INSPECTION. THE MECHANIC INFORMED THE DRIVER THAT THE ELECTRONIC CONTROL MODULE NEEDED TO BE REPLACED. PLEASE PROVIDE FURTHER DETAILS. *NM
NHTSA ODI #10111718
Mileage unknown · Dec 6, 2004
Exterior Lighting
THERE IS A WHITRE CLOUDY FILM ON THE HEADLIGHTS CREATING POOR VISABILITY AT NIGHT.*AK
NHTSA ODI #10102226
Mileage unknown · Dec 1, 2004
Engine And Engine Cooling
1996 FORD THUNDERBIRD 4.6L V8 MOTOR FAILURE OF PLASTIC INTAKE MANIFOLD. DRIVING HOME UNDER NORMAL CONDITIONS AND CHECK COOLANT LIGHT CAME ON. DUAGHTER SAID SHE HAD THOUGHT SHE SMELLED BURNING COOLANT FOR SEVERAL DAYS PRIOR. TOOK TO MECHANIC AND HE POINTED OUT THE CRACK IN THE INTAKE MANIFOLD. SAID THIS WAS A VERY COMMON PROBLEM …
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1996 FORD THUNDERBIRD 4.6L V8 MOTOR FAILURE OF PLASTIC INTAKE MANIFOLD. DRIVING HOME UNDER NORMAL CONDITIONS AND CHECK COOLANT LIGHT CAME ON. DUAGHTER SAID SHE HAD THOUGHT SHE SMELLED BURNING COOLANT FOR SEVERAL DAYS PRIOR. TOOK TO MECHANIC AND HE POINTED OUT THE CRACK IN THE INTAKE MANIFOLD. SAID THIS WAS A VERY COMMON PROBLEM WITH THIS MOTOR. PAID OVER $900.00 TO HAVE REPAIRED WITH UPGRADED PART. TOLD BY MECHANIC THAT RECALL ISSUED BUT EXPIRED ABOUT 6 MONTHS PRIOR TO REPAIR.*AK
WHEN IN THE SECONDARY LATCHED POSITION, THE DRIVER DOOR LATCHES MAY OPEN WHEN SUBJECTED TO TRANSVERSE LOADS LESS THAN THAT SPECIFIED IN FMVSS NO. 206, "DOOR LOCKS AND DOOR RETENTION COMPONENTS."
Consequence & remedy
Consequence: THE DRIVER'S DOOR, WHEN CLOSED ONLY TO THE SECONDARY LATCHED POSITION, MAY NOT SUSTAIN A 1,000 POUND TRANSVERSE LOAD.
Remedy: DEALERS WILL INSPECT AND, IF NECESSARY, REPLACE THE DRIVER DOOR LATCH.
UNDER CERTAIN CONDITIONS, THE CLIMATE CONTROL BLOWER DOES NOT OPERATE AS INTENDED. THE BLOWER COULD (1) STICK ON "HIGH;" (2) OPERATE ERRATICALLY WITH BLOWER OUTPUT VARYING BETWEEN NO BLOWER AND MAXIMUM BLOWER; OR (3) NOT OPERATE AT ALL DUE TO MALFUNCTION OF THE TEMPERATURE CONTROL MODULE.
Consequence & remedy
Consequence: BLOWER MALFUNCTIONS LIMITING OR STOPPING OUTPUT CAN ADVERSELY AFFECT WINDSHIELD DEFROSTING AND DEFOGGING PERFORMANCE INCREASING THE POTENTIAL FOR A VEHICLE ACCIDENT.
Remedy: DEALERS WILL REPLACE THE SEMI-AUTOMATIC TEMPERATURE CONTROL MODULES WITH MODULES CONTAINING REVISED SOFTWARE.
Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗
NHTSA investigations
0
No exact-year investigations in this snapshot.
1996 Ford Thunderbird Problems, Complaints & Recalls | Skip That Year