1996 Mercury Cougar

INTAKE MANIFOLD IS MADE OF PLASTIC. THERE WAS A FAILURE IN THE PLASTIC MATERIAL ON THE WATER CROSS-OVER JACKET (PORTION OF THE MANIFOLD). THIS CAUSED ALL THE COOLANT TO FLOOD OUT. I FOUND FORD HAD ISSUED A TSB (97M91) THROGH ITS OWNERS NOTIFICATION PROGRAM (ONP) IDENTIFYING FATIGUE AND FAILURE OF THIS PART. A NEW PART HAD BEEN DESIGNED BY FORD ENGINEERS THAT USED AN ALUMINUM COOLANT CROSS-OVER JACKET RATHER THAN THE PLASTIC. THE ONP TSB WAS RELEASED IN 1999. I CALLED THE SUPPORT PHONE NUMBER, 1-800-392-3673. IS NOW THE CLAIMS NUMBER. HOWEVER, HE INDICATED THE VIN NUMBER STILL SHOWED THE PREVIOUS OWNER. THIS WAS PROMPTLY CHANGED. IT TURNS OUT THE 7 YEAR EXTENDED WARRANTY ISSUED BY FORD (TO ALL NEW AND SUBSEQUENT OWNERS) HAD EXPIRED IN MAY OF THIS YEAR. HEAR IS MY PROBLEM: 1. I BOUGHT THE CAR(USED) FROM A MAJOR DEALER IN MARCH OF 2002. WHY DID FORD NOT HAVE MY OWNERS INFORMATION? WHAT GOOD IS THE ONP IF IT IS INACCURATE? 2. I HAD TO DO AN EXTENSIVE SEARCH TO FIND THIS TSB 97M91. HAD I KNOWN ABOUT THIS, I WOULD OF HAD IT REPLACED BEFORE IT FAILED, OR HAD IT PERIODICALLY INSPECTED.. I WAS NEVER GIVEN THE OPPORTUNITY TO MAKE THAT DESCISION. 3. IT SEEMS THE OWNERS NOTIFICATION PROGRAM ONLY BENEFITS THOSE WHO ARE "IN THE COMPUTER SYSTEM". 4. I FEEL I HAVE NO RECOURSE TO NEGOTIATE WITH FORD. THE CLAIMS PHONE NUMBER OFFERED NO ASSISTANCE TO THIS INQUIRY. 5. THIS IS A POORLY DESIGNED PART. SO POOR, FORD ISSED A 7 YEAR EXTENDED WARRANTY. WHAT MAKES THEM FEEL THEY HAVE NO OBLIGATION TO ITS CONSUMERS EVEN AFTER 7 YEARS? THIS IS A MAJOR SYSTEM COMPONENT. IT SHOULD HAVE A REASONABLE LIFE EXPECTANCY. IT WOULD NOT BE CONSIDERED ACCEPTABLE TO CRACK AN ENGINE BLOCK, HEAD, TRANSMISSION BELLHOUSING. SO WHY IS IT ACCEPTED THAT 7 YEARS IS ACCEPTABLE FOR AN INTAKE MANIFOLD? IT IS NOT NORMAL TO HAVE A 3 INCH FATIGUE CRACK IN AN INTAKE MANIFOLD. I FEEL FORD SHOULD INCLUDE MY VEHICLE IN A MANDATORY RECALL OF THIS PART.*AK

TEAR ALONG FRONT FACE OF UPPER INTAKE MANIFOLD. CALLED SEVERAL SALVAGE YARDS TO FIND REPLACEMENT AND WAS TOLD BY ALL THAT THEY CAN'T KEEP THESE IN STOCK. WHEN I DID LOCATE ONE THE MANAGER AT THE SALVAGE YARD ASKED WHAT HAPPENED TO MY INTAKE. I SHOWED HIM WHERE THE INTAKE SPLIT OPEN AND HE INFORMED ME THAT THEY'RE SEEING A LOT OF THESE WITH THE SAME PROBLEM AND I WAS LUCKY TO FIND THE ONE HE HAD. THIS PLASTIC (COMPOSITE) COMPONENT PROBABLY DOESN'T FAIR WELL IN ARIZONA. DT