Of o2 sensors, bad wire, and a leak-down test...

I remember our 96 GT had a recall involving the intake manifold which I believe is some kind of composite -- specifically, the intake manifold may become cracked or otherwise damaged and result in a vacuum leak.

Although I am not sure that this would result in a compression problem, it might very well result in rough idle and poor performance under less than wide open throttle.

Has your car had the intake manifold recall performed? If not you ought to get this done -- and I wonder if a leaking manifold might result in a too lean condition that could, if ignored for a long time, result in burned valves on the effected cylinder(s).

If compression is poor, it makes me think of several possibilities --

1. ring / piston failure (hope not)

1. valve not sealing properly (probably)

2a. burned / bent valve or valve seat failure (hope not)

2b. valve adjustment way too tight resulting in the valve not closing completely. (easiest to resolve if it is a simple adjustment issue)

Steve

Will I Am wrote:

Yes your car did have a recall I believe... sucks that MINE DIDN'T!! I have a 98 GT... replaced the intake manifold.. due to coolant leak near thermostat housing.

-Mike

98 GT

my dealer replaced my 96GT intake no charge a couple years back. The intake had a 7 year/100k extended warranty from Ford, therefore no more warranty for Will.

I would like to thank you for the replies everyone.

After reading said replies, I went online and found this:

Yes, there was a recall, and come Monday I will be down to my local (Raleigh NC) Ford dealer to see about getting that recall service.

HOPEFULLY that will solve the problem....

Again, thanks... We'll let you know what they say ;)

William

I wish you luck that this is the problem William.

If it were me I would scrub down the motor (when cool) with a solution of dawn dishwashing detergent and water using a long bristle brush to remove loose dirt and crud, and then rinse it off carefully and let it dry completely before taking it to the dealer. They don't always clean up the motor before doing major work and it would be a shame to have dirt fall into the motor when they yank the intake manifold.

Also, that way you will be able to jump on them if they return the vehicle to you with greasy hand prints and mung all over the motor after the work is complete!

Steve

Will I Am wrote:

Remove NO-SPAM from email address when replying

William, this does sound like a valve issue. Do you notice any smoke from the back end? If so, if its a light white smoogy smoke it could be a bad valve.Acceleration will cause more smoke out of the back end.

Mr. Ford wrote the following, which while being attributed to fact was none the less being challenged::

See, that's the thing. There is No Smoke whatsoever. None, nada, zippo...

It stumbles/no smoke at idle, it stumbles/no smoke at part throttle, it goes like hell/no smoke at anything near full/WO throttle.

I wouldl ike to say it does this -After- it warms up, but this isn't so. There is no apparent process or system to it.

Will I get it figured out? Yes. Will I do it before getting pissed off and spending some change? Yes, again.

But the next time -Anything- like this occurs again, will someone say "I know this problem! That happened to Will, it's _____________ !" ?

Yes, positively.

And that my friends, is the power of information.

Will I Am

Well, was told today at Capitol Ford, Raleigh, NC that my Mustang has lapsed for the recall replacement of the manifold. Seven year, 100,000 miles, and to quote CasinoMaker "'No more warranty for Will..."

I guess I'll have to shell out $400 for some rebuilt heads and $200 for a manifold.

I'm still not sure if that IS the cause, but it really, honestly sounds like a burnt vavle, possibly caused by a too-lean condition resulting from a cracked intake manifold.

The first pisser is that most of these problems seem to occur right at the 70K mile mark, and mine, while being a '96, has just a bit over

71,600. Sooo... I guess it was time for it to break.

Why doesn't anyone make an after-market manifold for these engines? You would think Edelbrock, 'The King of Intake Manifolds', at least would have some retro-fitting part, but no, they don't.

The second pisser is that I'll have to put another phenolic-resin (plastic) manifold back on. I really do not want to do that, becuase if I'm shelling out that much $$ to fix this, then am I asking too much for some decent parts? ;)

I'll keep everyone posted on what is happening with the car, but I don't expect it to be done by July 4th...

William

Yeah yeah yeah I know yer pissed, but shutup =). There is a revised intake manifold out that Ford dealerships sell. I bought mine for $140 and paid $200 to have it installed (give or take 20 bucks--can't remember the exact amount). The issue of the intake manifold cracking near the thermostat housing has been addressed (no longer plastic in that area & some other areas).

HTH.

-Mike

wrote the following, which while being attributed to fact was none the less being challenged::

I think it is almost impossible, physically, to piss me off ;)

Well, you wouldn't happen to have a part number for me?

Also, is this for the PI heads?

What IS the difference between NPI and PI heads, anyways? Anyone make an aftermarket/hotter cam for the SOHC head?

Will I Am

I am not so sure I would give up that easily will. I believe that Ford should have contacted you regarding the recall. If they didn't (and your address was still good) then they should still honor the recall.

Steve

Will I Am wrote:

steve wrote the following, which while being attributed to fact was none the less being challenged::

There's the rub: I bought this car -After- the 7y/100k limit ran out, according the the VIN which was ran through the PC at the Ford dealership.

Can you say the 'F' word? :)

Wm

PI heads are shaped differently & you need many other things besides just the heads... new valve covers, timing components I believe, etc. I'll try to dig up the URL... gimmie a sec..

Ah here it is...

Hope that helps... keep reading below.

I was jus' kiddin witcha.

No I don't, sorry. Ford dealerships *don't* sell the old manifold I'm pretty sure...

I am pretty sure the intake manifold will work with both NPI & PI heads.

PI heads have diff. shape & raise the compression.. which is where the HP is gained. PI cams also increase HP.

Good luck. =)

-Mike

98 Mustang GT

Nvm.. you need an '01 intake manifold. Sorry.

-Mike

Ford? (j/k)

Good luck.

By the way, does your 96 run hot? Ours did (here in So. Cal's dry climate it was VERY marginal at best) There was a TSB on this but Ford was never able to satisfactorily fix the issue on our mustang. Since we migrated to '98 GT's and cobra we have not had any overheating problems, in fact they run nice and cool even when flogged.

Steve

Will I Am wrote:

steve wrote the following, which while being attributed to fact was none the less being challenged::

;)

I think budget will have more of an effect than luck :/

Nope, doesn't run hot, stays at around 170-185 and it's summer in June here in NC.

I'm really scratching my head over this....

Wm I actually did shrug, fyi ;)

wrote the following, which while being attributed to fact was none the less being challenged::

Gonna bookmark that page, I am I am.

I don't mind changing everything over to the PI party, because as it looks I'll have to have some new heads and an intake anyways, so really, if I go this far I would be stupid not to go up to the next level (so to speak) while I have this thing blown apart.

If we can't laugh at ourselves, then who can we laugh at best? :)

But I want the new manifold, the revised manifold, > The Manifold For The Ages....

Well ok.

So no after-market cams then...

What exactly do they make for these engines? Seems to be: nothing.

Thanks!

Will I Am trying to be positive ;)

wrote the following, which while being attributed to fact was none the less being challenged::

So is this the 'refined' intake you mention in the other post??

Wm