Which parts fail
Components named in complaints (fuel pump, injectors, fuel tank, hybrid and EV propulsion).
Owner reports
Selected complaints filed with NHTSA by 1996 Mercury Grand Marquis owners, lightly cleaned up (personal details are redacted by NHTSA).
The affeced engine is the 4.6l engine with the defective plastic intake manifold part number f8az-9424-bc* installed in 1996 and up all crown vics,Grand Marquis and town cars. This is a very serious safety issue. Consider a family of 6 traveling an interstate, at highway speeds, when the defective intake manifold gives out and a rapid loss of coolant occurs. The driver panics and tries to get to the right shoulder, only to be hit by an 18-wheeler. Or the driver gets to the right shoulder and a highway patrolman stops to render assistance and eventually, a tow truck shows up to tow the vehicle. All these people are in harms way, because the defective intake manifold was not put on the recall list. …
My primary complaint is the stress crack on the intake manifold. This is a known problem by Ford, and has been the subject of a recall program for their fleet vehicles only. The coverage is for 7 years from the vehicles warranty start date, with no mileage limitation. It covers the intake manifold for 4.6 l sohc engines on 1996-2001 crown victoria police vehicles, certain 1998 through 2001 crown victoria taxis and certain 1998-2001 Lincoln town cars, all using the same intake manifold as that on my Grand Marquis (same part number, same part!). The recall program is 01m02. The stress crack caused complete coolant loss and overheating of the engine at highway speeds and the release of coolant onto the windshields of following vehicles. In addition, the reel-type electric window system in the car fails in more than normal fequency. I have had three failres in the past two years.
While driving along a busy city street on a cold evening in January I noticed a cloud of steam behind me. It obscured my view of traffic behind me and their view of my vehicle. After pulling of the right-of-way, and examining the engine compartment, I recognized cooling system failure but was unable to identify the source of the problem. It was later determined that the "plastic" intake manifold had ruptured and sprayed coolant all over the engine cmpartment,and hot exhaust manifold, etclocal Ford dealers were closed and unavailable. Reputable auto repair garage performed the necessary repairs (6 hrs) this critical engine component should "never" fail. Ford quietly recalled police, fleet and emergency vehicles. Consumers were left to fend for themselves. They have ignored my request for financial assisstance.
Plastic intake manifold busted losing antifreeze,the sensor could not work, it only works with coolants, due to this the gauges did not work, until the the check engine light came on then I is to late. I was lucky I wasn't going 65 down the expressway when the motor locked up. I'm sure this has happen and cause accidents and no one knew what caused it. I have checked with 4 certified technicians they told me the problem happens often with this plastic intake manifolds. Why would anyone have a plastic intake so close to a hot! Motor. I am also told that they did recall some vechile with this motor and plastic intake but not on this car. This could have been a very dangerous things if I have been going faster, are if I was not an experience driver.
The intake manifold on my vehical is the same that is on any 4.6ltr engine that Ford has put into production in the years prior to 1998. When Ford went to a casted manifold. I know they have had several failures of this part. Even the local dealership parts man said that this part should be recalled. That tells me that they have had a high percentage of failures of this manifold. But instead the consumer has to put out around 500 dollars, to repair a defective part. Is there any recourse for this type of problem. I noticed several of the same complaints in your listing of failures.
Intake manifold is plastic and has the potential to melt. Consumer is concerned that this could eventually cause other problems to occur, such as engine over heating. There are stress cracks where the alternator is attached to plastic manifold. The dealer informed consumer that the defective part should be under recall but it wasn't. At first, Ford stated they would pay for the part, however they have now declined. This is a saftey hazard as smoke emits from the engine area obstructing the view of the driver.
Air intake plenum developed a crack which in turn sprayes coolant onto the rear of the alternator. I know there are many problems with this part but Ford will not replace it.there is a limited recall on this part but it begins less than 4 months after the build date on my car, even though the problem described exists on many earlier models. I would like my car included in this recall but am told no way by Ford. Any help in this matter would be greatly appreciated.
Today was the third time that I have refueled the car and have noticed that there is a strong gas smell when I park the car in the garage. I have looked with a flash light under the car (left rear below the tire rim) and I see gas dripping out of where a tubing connects to the fuel tank. This is a rapid drip that leaves a puddle on the floor. I have been cautious to not "over-fill" and still the problem persists.
The water jacket on the intake manifold cracked right behind the alternator the dealers cary atleast 6 manifolds in stock at all times they had the problem on other vehicles and told me mine wasnt on the list.
Vehicle stalls, mostly while making turns at slow speeds. Dealer feels cause is overfilling of fuel filler neck. Dealer replaced filler pipe, however consumer states vehicle is still stalling.
NHTSA investigations
Post rear end collision fires
There is no summary currently available
Fuel System complaints in other Grand Marquis years
Frequently asked questions
How common are fuel system problems on the 1996 Mercury Grand Marquis?
NHTSA has 21 complaints about the fuel & propulsion system of the 1996 Mercury Grand Marquis, 9% of the model year's 239 complaints. The component named most often is carburetor system (16 mentions).
Is there a recall for 1996 Mercury Grand Marquis fuel system problems?
No. NHTSA lists no fuel & propulsion system recall for the 1996 Mercury Grand Marquis, though it has 5 recalls for other components. If the problem is widespread, a repair may still be covered by an extended warranty or a manufacturer service bulletin — ask a dealer.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.