1996 MERCURY COUGAR Complaints

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

TEMPERATURE GAUGE WENT UP, CAR OVERHEATED. TOOK VEHICLE TO INDEPENDENT SHOP, AND TECHNICIAN STATED THAT INTAKE PLASTIC MANIFOLD CRACKED.*AK

WHILE DRIVING AT 40 MPH AND WITH NO WARNING. THE HOOD FLEW OPEN. DEALER NOTIFIED. *AK *SCC *JB

THERE WAS A LOUD KNOCKING NOISE FROM UNDER THE HOOD, AND HAD TAKEN THE VEHICLE TO SEVERAL PEOPLE AND WAS TOLD THAT IT WAS SOMETHING INTERNAL AND WILL NEED A NEW ENGINE. THE CONSUMER WOULD LIKE TO KNOW IF THERE WAS A DEFECT IN THE MANUFACTURING. *SCC

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

THE IGNITION HAS FAILED ON TWO OCCASIONS. CAR WOULDN'T SHUT OFF BY IGNITION KEY. HAD TO SHUT OFF VIA FUEL SHUTOFF. MR

VEHICLE WAS GOING 20MPH RIGHT BALL JOINT LOCKED UP. VEHICLE STEERED STARIGHT, BUT WAS PULLING RIGHT. EVERTUALLY, VEHICLE STOPPED ITSELF. MERCURY DEALER WAS NOTIFIED.*AK

ON FIVE OCCASIONS WHILE DRIVING VEHICLE STARTED TO ACCELERATE INTERMITTENTLY. VEHICLE BEEN TO DEALER ON TWO OCCASIONS, AND THEY COULD NOT DUPLICATE THE PROBLEM. FEEL FREE TO PROVIDE ANY FURTHER INFORMATION.*AK

WHILE TRAVELING ON I-4 FROM TAMPA, THE LEFT REAR TIRE TREAD SEPARATED FROM THE TIRE. APPROXIMATELY 15 TO 20 INCHES OF TREAD BECAME SEPARATED.*AK

THE CONSUMER HAD A RECALL FOR ENGINE. DEALERSHIP REPLACED DEFECTIVE PART FROM RECALL. SIX MONTH LATER, REPLACEMENT PART DIDN'T WORK. DEALERSHIP MECHANIC TOLD HER THAT SHE NEEDED A NEW ENGINE. ENGINE LIGHT CAME ON WHILE CONSUMER WAS DRIVING. AND STAYED ON. SHE COMPLAINED THAT ENGINE COOLANT WAS RUNNING OUT FROM UNDERNEATH VEHICLE. VEHICLE WOULDN'T MOVE. VEHICLE HAD TO BE TOWED. CONSUMER WAS CONCERNED THAT REPLACEMENT PART DIDN'T WORK AT FIRST, AND SHE NEEDED SOME HELP FROM FORD MOTOR COMPANY.*AK