My car has had this problem for at least six or seven months. The intake manifold has a small crack that allows coolant to pool in the #4 spark plug well. I've tried both patching and diverting the flow with only the small amount of limited success you would expect. Whenever one of these methods fails I'm left with a dead cylinder.

Here's the real kicker though, I just now found out Ford knew about the problem, was sued in a class action and settled. Some websites claim that only taxis and police cars are covered in the settlement (mine is an ex-police car) other web sites say all owners of affected cars are covered, but it doesn't matter because all dealer repairs or claims for reimbursement on previous repairs had to be submitted by no latter than March 16,06.

If your manifold had not failed by this time they would extend your warranty out seven years from the original date of purchase. (Once again web sites disagree on whether or not this was for fleet buyers only or for all affected cars)

They also claim all owners were notified of the problem within the alloted time to make claims. I was never notified, I've had the car since '04 it is a 2000 so now the warranty time is up and I may be stuck.

Had I actually been notified I may have been able to squeak in before the deadline, or at least been able to take some action, it's not a cheap repair.

Any suggestions would sure be appreciated.

A few of the sites

http://www.lrolaw....ail&iLawsuitId=557


http://www.fordmanifoldsettlement.com/


http://en.wikipedi...ord_Modular_engine


-CO

My suggestion? Get all the parts, and swap the manifold, gaskets, TB... all yourself. You'll need basic sockets, wrenches, screwdrivers, and extensions, and that's it. Pretty straight-forward. All the plugs you can tape and label.

Take a weekend, have some pride in your vehicle by doing the work yourself, while also saving monies!

I'm pretty sure you'll find your problem circled in blue

while you have the intake off, replace the heater line that runs under the intake... oh that was a brilliant design Ford.

Id rather deal with a manifold than changing plugs and coil packs on a modular motor. It took me 8 hours to do the plugs on the 5.4 in my lifted Expedition, and 3 hours on my dads 4.6.

I didn't buy it, it was my ex's car she didn't want it any so I'm driving for now while I'm working on my Tahoe.