PI Manifold cracked around water housing.

try and get it replaced again...you may still be under the extended 7 year warranty on intakes. Is it still the all plastic piece?

you should try to take it back on the recall. If not, your choices are limited, suck, and cost lots of Dinero

FWIW, I had my coolant temp. sensor JB welded into my intake for 2 years and never had it blow out. Reason I JB'd it in the first place is because one day the sensor just blew out and stripped the threads. Recently my intake busted where yours did so I replaced it. JB should work for a while if the crack is not too big. Ultimately you need to replace it, but I'd see if it can be done under warranty before I spent the money.

dmontzsta said:

Whats the best way to go about the recall? I am not good at arguing with people. Is there some solid proof I can bring in to the dealer? or give them over the phone? Problem is, now I dont want to JB weld it, cause they might not cover it and I cant drive it, cause it is spewing coolant all over the place.

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just go to the nearest Ford and have them check your in service date...if your under 7 years they will replace it with the metal crossover version. If your out of your 7 years then you can buy a new one for $150 from www.karkraft.com and its an easy swap.

I did JB weld and it worked for about 2 weeks. I'd try to get your money back. Just call em after hours and leave a mesage or just show up. It's worth the try.

dmontzsta said:

I am going to JB weld and seal it with silicone for now...but this is only a temp fix.

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it doesn't work

Call a local Ford dealership, ask to speak with the service manager. Tell the service manager that your intake has been replaced once and you don't know why it was replaced with another intake manifold with the plastic runner. Ask if it can be replaced with the intake manifold with the aluminum crossover under warranty since the replacement has cracked. You won't have to argue with them. Have your VIN number handy because they will check the system to ensure that it has been replaced before and your chance of having it replaced again should be pretty good.

Tell them it is your daily driver (only car) and you need reliable transportation ... you just want to have the intake fixed properly. Tell them that you are pretty sure that your car is still covered under the seven years allowed by the settlement of the class action law suit regarding your intake manifold. If the service manager says he/she doesn't think they can do anything for you, ask them "Who would you recommend that I talk to that may be able to help me?"

Just be polite and assertive, you should have decent luck considering that your car is a 1999.