Owner-reported complaints naming the engine system, filed with NHTSA
Data refreshed
Reports naming the engine itself — including stalling, misfires, oil consumption, cooling and internal engine components. Every record below is an owner-reported complaint about the 1996 Ford Thunderbird submitted to NHTSA — not a confirmed defect, not a recall and not a manufacturer bulletin. 65 reports on file name it.
Complaints are reports submitted by owners and drivers to NHTSA. They are not verified and do not establish that a defect exists.
The 25 most recent of 65, in the owner's own words
TL* THE CONTACT OWNS A 1996 FORD THUNDERBIRD. THE CONTACT WAS DRIVING 30 MPH WHEN HE NOTICED AN ABNORMALLY STRONG COOLANT ODOR. THE CONTACT THEN INSPECTED THE VEHICLE AND FOUND THAT THE ANTIFREEZE INTAKE MANIFOLD HAD FAILED. THE INTACT MANIFOLD WAS CRACKED AND CAUSING ANTIFREEZE TO SPILL. THE VEHICLE WAS NOT TAKEN TO THE DEALER TO BE DIAGNOSED OR REPAIRED. THE FAILURE AND THE CURRENT MILEAGE WAS 60,000.
DEFECTIVE INTAKE MANIFOLD. FORD REPLACED ONCE, FREE OF CHARGE @ 48,523 MILES. CRACKED AGAIN @ APPX. 95,700 MILES. FORD REFUSED TO REPLACE FREE OF CHARGE. REPLACED ONE DEFECTIVE MANIFOLD WITH ONE THAT WAS JUST AS DEFECTIVE. THERE WAS A CLASS ACTION SUIT ON THIS MANIFOLD, IT WAS SO BAD. *JB
INTAKE (PLASTIC) CRACKS ;LEAVING FAMILY AND I STRANDED ON 30 MILE STRETCH OF HIGHWAY WITH NO HOUSES OR BUSINESS. TOWED TO STATION AND FIXED RECALLED INTAKE. TAXI COST HOME AND BACK 2 DAYS LATER TO RETRIEVE CAR SOON STARTED HAVING HEATER COIL LEAKS AND OVERHEATING;ANTIFREEZE CAUSING HEADACHES. ALMOST $1000.00 TO REPLACE 30 DOLLAR PART(DASH BOARD AND CONSOLE REMOVED AND AIR CONDITION UNIT DISCONNECTED AND RECHARGED) DEALER TOOK COST OF NEXT 2 REPLACEMENT HEATER COILS AND IT STILL NEEDS 4TH;NO HEAT;STILL LEAKS ANTIFREEZE INSIDE CAR. INTAKE MANIFOLD(PLASTIC) CRACKED AGAIN;OVERHEATED AND BURNT ME THIS TIME ALSO CAUSING SERIOUS DAMAGE TO CAR;VERY COSTLY WHICH I GUESS WE THE CONSUMER WILL HAVE TO BEAR. HOW MANY COMPLAINTS DOES IT TAKE? *TR
TL* - THE CONTACT WANTED TO HAVE REPAIR DONE TO 1996 FORD THUNDERBIRD, HOWEVER SERVICE BULLETIN #97M91, DATED JAN 19, 1998 (NHTSA ITEM NUMBER: 605621) EXPIRED AND FORD CHARGED FOR THE REPAIRS. THE MILEAGE AT THE TIME OF THE FAILURE WAS 80000. THE CONTACT SAID THAT THE SERVICE BULLETIN WAS FOR THE INTAKE MANIFOLD. THE CONTACT WROTE TO FORD. THE REFUSED TO HONOR THE SERVICE BULLETIN. *AK UPDATED 2/6/2007 - *NM
DEFECTIVE INTAKE MANIFOLD ON 1996 FORD THUNDERBIRD. THE CAR ONLY HAS 84,450 MILES ON IT! COST WAS $1002.02 TO REPAIR. WHY IS THE CONSUMER BEING CHARGED FOR THIS COSTLY REPAIR WHEN THIS IS A KNOWN DEFECTIVE PART FROM THE FORD MOTOR COMPANY?*JB
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)
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
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
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
3.8 CYLINDER HEAD FAILURE
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
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
COOLANT FUMES/ODOR WAS COMING INSIDE THE VEHICLE WHILE DRIVING AT ANY SPEED. CONSUMER INSPECTED THE VEHICLE AND FOUND A CRACK IN THE INTAKE MANIFOLD. CONSUMER NOTIFIED THE DEALER, WHO INFORMED THE CONSUMER THAT THIS VEHICLE WAS NOT COVERED UNDER A PRESENT RECALL.*AK
1996 FORD THUNDERBIRD 4.6L 281CID V8 MOTOR FAILURE OF PLASTIC INTAKE MANIFOLD. DRIVING HOME UNDER NORMAL CONDITIONS AND CHECK COOLANT LIGHT CAME ON. WIFE 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 $800.00 TO HAVE REPAIRED WITH UPGRADED PART. FORD MOTOR CO. HAS BEEN AWARE OF PROBLEM FOR YEARS AND ISSUED A RECALL FOR TAXIS AND POLICE VEHICLES BUT RECALL DOES NOT COVER PRIVATELY OWNED VEHICLES. CAR HAS APPROXIMATELY 114,000 MILES.
I WAS TOLD THAT THEIR IS A RECALL ON MY 1996 FORD THUNDERBIRD FOR A FAULTY INTAKE COOLING MANIFOLD. CAN YOU PLEASE CONFIRM THIS. I DO NOT SEE IT ON YOUR RECALL LIST. *JB
WHILE DRIVING CONSUMER NOTICED SMOKE COMING FROM THE FRONT OF THE VEHICLE. CONSUMER WAS ABLE TO MAINTAIN CONTROL OF THE VEHICLE, AND DROVE IT TO A BODY SHOP. MECHANIC DETERMINED THAT THE INTAKE MANIFOLD WAS CRACKED AND NEEDED TO BE REPLACED. *AK
VEHICLE'S INTAKE MANIFOLD CRACKED ON 1996 FORD THUNDERBIRD.*MR THE VEHICLE INTAKE MANIFOLD FAILED AND WAS REPLACED UNDER RECALL. ABOUT ONE YEAR AFTER THE INTAKE MANIFOLD WAS REPLACED THE CONSUMER STARTED SMELLING ANTIFREEZE INSIDE THE VEHICLE. THE VEHICLE WAS TAKEN TO THE SHOP WHERE THE CONSUMER WAS TOLD THAT DROPS OF ANTIFREEZE COULD BE SEEN BY THE WATER PUMP AND THAT IT NEEDED TO BE REPLACED. AFTER IT WAS REPLACED THE CONSUMER CONTINUED TO SMELL ANTIFREEZE. IT WAS LATER DETERMINED THAT THE MANIFOLD CRACKED AGAIN AND THAT THE ANTIFREEZE HAD SOAKED THE FIRST TWO CYLINDERS CAUSING THEM TO MISFIRE. THE CONSUMER WAS RESPONSIBLE FOR REPLACING THIS MANIFOLD. *NM
PROBLEMS WITH THE INTAKE MANIFOLD ON 1996 FORD THUNDERBIRD.*MR THE VEHICLE'S INTAKE MANIFOLD CRACKED. THE MANIFOLD WAS REPLACED, FREE OF CHARGE, WITH ANOTHER PLASTIC MANIFOLD DUE TO A RECALL. APPROXIMATELY A YEAR AFTER THE MANIFOLD WAS REPLACED THE CONSUMER STARTED SMELLING ANTI-FREEZE INSIDE THE VEHICLE. IT WAS LATER DETERMINED THAT MANIFOLD CRACKED AGAIN AND ANTI-FREEZE SOAKED THE FIRST TWO CYLINDERS WHICH CAUSED THEM TO MISFIRE. THE CONSUMER IS SEEKING REIMBURSEMENT. *NM
IN FEBRRUARY 2003, MY 1996 FORD THUNDERBIRD 4.6L STARTED SPEWING WHAT I THOUGHT WAS SMOKE FROM THE ENGINE COMPARTMENT. I WAS JUST AT MY DRIVEWAY AND PULLED IN. AFTER OPENING THE HOOD I REALIZED IT WAS NOT SMOKE BUT COOLANT THAT WAS BEING SPRAYED ALL OVER THE HOT ENGINE. I HAD THE CAR TOWED TO FRIENDLY FORD IN LAS VEGAS, NEVADA, WHERE I HAD BOUGHT THE VEHICLE, AND AFTER SOME DISCUSSION, THEY REPLACED THE INTAKE MANIFOLD UNDER A TSB. ON 6-2-04, SOME 16 MONTHS LATER, THE INTAKE IS AGAIN LEAKING. AFTER DOING SOME RESEARCH, I FOUND THAT THE PART THEY PUT ON THE CAR IS NOT THE RECOMMENDED PART AS STATED IN A LETTER FROM FORD MOTOR COMPANY IN FLINT, MICHIGAN,DATED DECEMBER 2001. THE PART WHICH FORD STATES IS THE REPLACEMENT PART IS F6AZ9424AA. THE PART LISTED ON THE REPAIR INVOICE IS F8AZ8424AAA. THE PART ACTUALLY INSTALLED ON THE CAR HAS A PART NUMBER OF AE9424CA. I TALKED TO THE SERVICE MANAGER, DENNIS EICH, AT FRIENDLY FORD ON 6-22-04, WHO STATED THAT THE PART NUMBER DOESN'T MATTER, THEY DON'T NEED TO INSTALL THE PART RECOMMENDED BY FORD IN THE LETTER, AND BECAUSE THE PART IS OUT OF WARRANTY NOW THEY WON'T FIX IT CORRECTLY. I UNFORTUNATELY AM NOT ALONE IN THIS PROBLEM. MY RESEARCH, VIA THE INTERNET, SHOWS NUMEROUS COMPLAINTS OF THE SAME PROBLEM. THIS IS A MANUFACTURERS DEFECT WHICH SHOULD BE SUBJECT TO A FULL BLOWN RECALL AND FORD SHOULD BE REQUIRED TO REPAIR THE VEHICLES WITH THE RECOMMENDED PARTS.*AK
WHILE DRIVING 40 MPH VEHICLE STALLED. THIS CAUSED LOSS OF STEERING AND BRAKES. VEHICLE WAS TOWED TO THE INDEPENDENT SHOP, AND MECHANIC DID NOT KNOW WHAT WAS WRONG WITH THE VEHICLE. *AK
THE CONSUMER'S 1996 FORD THUNDERBIRD COMPLETELY BROKE DOWN DUE TO THE FAILURE OF THE PLASTIC INTAKE MANIFOLD. *PH THE VEHICLE WAS PURCHASED NEW AND THE CONSUMER WASN'T GIVEN PRIOR WARNING THAT THIS EXISTED. THE DEFECTIVE PART WAS ON THE VEHICLE BETWEEN THE DATES OF MAY 1996 AND FEBRUARY 2004. THE MANIFOLD WAS FOUND CRACKED. FORD MOTOR ISSUED PROGRAM #97M91 IN RE TO VEHICLES BUILT WITH THE PLASTIC MANIFOLD. THE CONSUMER REQUESTED REIMBURSEMENT. *SC *JB
HEAD GASKETS FAILED RUINING MY CYLINDERS AS WELL WHILE DRIVING ON THE HIGHWAY WITH MY CHILDREN. BARELY GOT THE CAR HOME WITH A CLOUD OF WHITE SMOKE. I CANNOT AFFORD TO FIX THIS THE CAR HAS BEEN SITTING FOR ALMOST 1 AND A HALF MONTHS, AND I STILL OWE 5900 DOLLARS ON IT. I HAVE TO RIDE MY BIKE TO WORK OVER 3 MILES EACH WAY AND RENT A CAR FOR THE WEEKENDS COSTING ME A FORTUNE. I BELIEVE THEY NEED TO PAY FOR MY ENGINE TO BE REBUILT ESPECIALLY AFTER READING ALL THE ARTICLES OF HOW THE 3.8 LITRE V6 ENGINE HAS FAILED CONTINUOUSLY THROUGHOUT THE YEARS AND FORD HAS KNOWN IT. I LOVE FORDS AND HAVE NEVER DROVE ANYTHING ELSE. I AM IN A SERIOUS BIND AND NEED HELP FOR SOMETHING THAT FAILED DUE TO A DEFECTIVE PART. THANK YOU FOR LISTENING AND I HOPE FORD GETS THE MESSAGE. DEREK HAUGH
CRACKED PLASTIC INTAKE MANIFOLD THAT CAUSED A MAJOR COOLANT LEAK. *LA
IN OCTOBER OF 1998 VEHICLE WAS REPAIRED UNDER A RECALL FOR THE INTAKE MANIFOLD. CURRENTLY, THE VEHICLE OVERHEATED DUE TO A CRACK IN THE INTAKE MANIFOLD. *AK WHEN THE INTAKE MANIFOLD IS REPLACED, THE OLD STYLE IS USED WHICH IS WHY THE CONSUMER BELIEVES IT FAILS AGAIN. CONSUMER FEELS FORD SHOULD REIMBURSE HIM THE COST OF REPAIRS. *PH
MY COMPLAINT IS ABOUT THE CRACKED INTAKE MANIFOLD CURRENTLY SITTING IN MY 1996 THUNDERBIRD 4.6L ALTHOUGH I CAN FIND ONLY A LITTLE BIT OF INFORMATION ON THIS MATTER REGARDING RECALLS; CLASS ACTION SUITS; AND FREE OF CHARGE REPLACEMENTS; I AM VERY INTERESTED IN FINDING OUT IF THERE IS ACTUALLY ANYTHING LIKE THAT HAPPENING AND TO FILE MY COMPLAINT AND/OR JOIN ANY OTHER CONSUMER WHO IS HAVING THE SAME PROBLEM ON ANY CLASS ACTION SUIT.*AK
Higher-selling and older vehicles accumulate more reports. Counts are not failure rates and are not directly comparable between vehicles that sold in very different numbers.
Categories with enough reports to have a page of their own
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