NHTSA Complaint #10112480 — 1997 FORD F-150

I HAVE A 1997 FORD F-150, WITH A 4.2 LITER ENGINE, AND 82,000 MILES ON THE VEHICLE. FOR THE PAST FEW YEARS I NOTICED A GRADUAL DECREASE IN THE COOLANT LEVEL, HOWEVER, I COULD NOT DETERMINE WHERE THE LEAK WAS OCCURRING. ALSO, FOR THE LAST THREE WEEKS LEADING UP TO THE OCCURRENCE, I NOTICED THE ENGINE WOULD KNOCK WHEN I WOULD START IT UP. IN OCTOBER OF 2004, AFTER STARTING THE TRUCK, I SAW WHITE EXHAUST SMOKE AND HEARD THE #1 PISTON RATTLING. I HAVE SINCE FOUND OUT THAT THIS IS A COMMON OCCURRENCE WITH OWNERS OF '96 THRU '98 MODEL FORD CARS AND TRUCKS, WITH 3.8L AND 4.2L ENGINES. I HAVE ALSO SEEN FORD TSB'S THAT PROVE THEY HAVE KNOWN FOR ABOUT SIX YEARS, THAT THE FRONT COVER GASKETS HAVE A HIGH INCIDENCE OF FAILURE, CAUSING COOLANT TO LEAK INTO THE CRANKCASE. ALSO, THAT THE INTAKE MANIFOLD GASKETS CAN FAIL, WHICH CAUSES COOLANT TO LEAK INTO THE #1 CYLINDER. WHEN AN ENGINE IS STARTED WITH WATER IN THE CYLINDER, THE PISTON ROD IS LIKELY TO BED OR BREAK. THE MANIFOLD GASKET FAILURE IS RESPONSIBLE FOR MY PROBLEM, AS WELL AS THAT OF MANY OTHER FORD OWNERS. THE REMEDY FOR THE PROBLEM IS AN ENGINE REPLACEMENT, COSTING ABOUT $4,000. FORD MOTOR COMPANY IS NOT TAKING RESPONSIBILITY FOR THIS ENGINEERING DEFECT, LEAVING MANY UNSATISFIED CUSTOMERS TO PAY FOR THEIR FAULTY ENGINES. I HAVE NOT HAD MY ENGINE REPLACED YET. *JB