Nuts and Bolts with Buffalo Jim

I hate to be the bearer of bad tidings, but you've fallen victim to one of the biggest automotive industry screw-jobs of the last decade. The first time I saw the problem you're describing, I was stumped--no leaks, no overheating, just a whoosh that sounded like running water. We eventually isolated the intake manifold as the source of the sound, but we couldn't find anything wrong with the thing. We finally popped the manifold off and discovered several hairline cracks in the area around the thermostat housing. These cracks were disturbing the coolant flow and creating what you correctly characterize as a "washing machine" sound.

The bad news is that the only way to fix the problem is to replace the part and the worse news is that the service could cost as much as $1,000. But the worst news of all is that Ford is 100 percent aware that the manifold is faulty but has made no effort to remedy the problem for thousands of drivers.

About 10 years ago, a panel of engineers at Ford decided to start casting the intake manifolds for Crown Victorias, Thunderbirds, Mercury Grand Marquis and Lincoln Town Cars out of polycarbon--basically, a high-tech plastic--instead of iron or aluminum. This design had several problems, not the least of which was the fact that this plastic had to hold hot, pressurized coolant whenever the car was running. Over time, the manifold tended to crack and eventually would begin leaking coolant.

Ford did issue a limited recall of the part but only for certain 1996-2001 Crown Victoria Police Interceptor models and 2001 Crown Victoria taxis. To quote from Ford Technical Service Bulletin 01M02: "A fatigue crack may develop in the composite intake manifold used on the 4.6L SOHC engine installed in your vehicle. This condition may result in engine coolant leakage, which, if not serviced, may cause engine overheating. Complete loss of coolant may result in engine damage or engine failure."

Unfortunately, Ford didn't include anything but fleet vehicles in the recall, so lowly consumers like you and I have to shell out the $600 for the factory replacement part plus several hundred dollars in labor cost. I even called the Ford dealer myself and was transferred to three different people before being curtly informed that the recall did not cover your particular vehicle. I'm sorry to say it, but you're just going to have to suck it up and pay for the service. Just remember this the next time you buy a car. And don't hesitate to make Ford aware of your displeasure at:

Ford Motor Company

Customer Relationship Center

P.O.Box 6248

Dearborn, MI 48126

Tip of the week

Speaking of expensive repairs, I think the most common question I hear at the shop these days is, "Why does it cost so much to get my car fixed?" This is a complicated question that has everything to do with the evolution of cars over the past three or four decades. Back in the day, problems could be diagnosed, engines overhauled, electrical systems repaired, pumps resealed and carburetors rebuilt--all with good instincts and a set of standard tools.

Nowadays, this is barely enough to do an oil change. Mechanics have to attend years of training to understand the ins and outs of computer-controlled transmissions and anti-lock braking systems. Gone are the days of the do-it-all mechanic. Now most shops have specialty mechanics who only work on certain types of jobs. There are more rules and more regulatory agencies than ever--EPA, DMV, OSHA--and cars routinely go over 200,000 miles. The four cycles of the engine are the same, but when you pay $60-$75 an hour for labor, you're really footing the bill for computers, tools, training and the mechanic's know-how.

Buffalo Jim is the owner of Allstate Auto Marine. When he opened his shop in 1970, he charged $10 plus parts for a tune-up. A complete air-conditioning service cost $2.95 plus 19 cents a pound for Freon. The average car held four pounds. E-mail him your car questions at buffalojim@lasvegasmercury.com.