2001 Ford Crown Victoria

The composite (plastic) intake manifold on the 4.6L Modular V8 is prone to cracking at the coolant crossover passage, causing an external or internal coolant leak. Internal leaks can allow coolant to enter the engine oil or combustion chambers, while external leaks produce visible coolant dripping. This affects most Panther-platform vehicles from 1996-2011.

Replace the intake manifold with an updated design that features an improved coolant crossover. Dorman and other aftermarket brands offer reinforced replacement manifolds. Replace all intake gaskets and the thermostat while the manifold is off. Flush the cooling system after repair.

Crown Victorias equipped with the optional rear air suspension (common on Police Interceptor models) experience air spring bladder leaks and compressor burnout. The rear of the vehicle sags overnight, and the compressor runs continuously trying to maintain ride height until it overheats and fails.

Replace the failed air springs with new air spring assemblies or convert to conventional coil springs using a conversion kit. If converting, install a bypass module to eliminate the suspension warning light. Replace the compressor if it has burned out.

The HVAC blend door actuator frequently fails, causing the climate control to blow only hot air, only cold air, or different temperatures on each side. A clicking or tapping noise behind the dashboard when the HVAC is turned on is a telltale sign of a failing actuator motor.

Replace the blend door actuator. On the Crown Victoria, the driver-side actuator is accessible from under the dashboard without removing the entire dash assembly. The passenger side is more labor-intensive. Use a Motorcraft actuator for reliability.

The 4R75E four-speed automatic transmission develops a torque converter shudder felt during light throttle acceleration between 35-55 mph. The vibration is caused by worn torque converter clutch lining material contaminating the transmission fluid. High-mileage police interceptor models are especially prone.

Perform a complete transmission fluid flush with Mercon V fluid. If the shudder returns, the torque converter needs replacement. For police interceptor models with heavy use, consider installing a heavy-duty aftermarket torque converter. Regular fluid changes every 30,000 miles help prevent the issue.

The front lower ball joints wear out prematurely, causing a clunking noise over bumps, uneven tire wear, and a loose or wandering feel in the steering. Police interceptor models with heavy use and high mileage are especially susceptible. A severely worn ball joint can separate, causing loss of steering control.

Replace both lower ball joints as a pair. Perform a front-end alignment after replacement. Inspect the upper ball joints, tie rod ends, and sway bar end links at the same time, as they often wear simultaneously on high-mileage Panther-platform vehicles.

Dorman Products, Inc. (Dorman) is recalling certain model Dorman Steering Shafts, part number 425-359, Solutions Steering Shafts, part number 7-0359, and OE Solutions Steering Shafts, part number 425-359, manufactured April 17, 2014, to September 28, 2015. These aftermarket replacement steering shafts are sold for use in 1995-2002 Ford Crown Victoria, Mercury Grand Marquis, and Lincoln Town Car vehicles. These steering shafts may separate during operation if the integral fastener is loose or missing and if the interfacing vehicle shaft is compressed in length.

If the shafts separate during vehicle operation, a loss of steering control would result, increasing the risk of a vehicle crash.

Dorman will notify owners, and dealers will replace the steering shaft, free of charge. The recall began on October 28, 2015. Owners may contact Dorman customer service at 1-800-523-2492, option 5.

CERTAIN AFTERMARKET FUEL FILTERS SOLD UNDER THE PUROLATOR BRAND NAME, P/N F65277, SHIPPED FROM JANUARY 16 THROUGH JUNE 2, 2006, FOR USE ON THE ABOVE LISTED PASSENGER VEHICLES. DUE TO INCORRECT DESIGN, THE QUICK CONNECTORS MAY NOT FULLY SEAT WITH THE TUBE INTERFACE, EVEN THOUGH THE PERSON MAKING THE CONNECTION MAY BELIEVE THAT THE QUICK CONNECTOR IS FULLY ATTACHED.

FAILURE OF THIS CONNECTION COULD LEAD TO FUEL SPILLAGE AND, IN THE PRESENCE OF AN IGNITION SOURCE, A FIRE COULD OCCUR.

UFI WILL NOTIFY OWNERS AND REPLACE THE FILTERS FREE OF CHARGE. THE RECALL BEGAN ON AUGUST 4, 2006. OWNERS MAY CONTACT UFI FILTERS USA AT 800-230-5876.

ON CERTAIN NATURAL GAS VEHICLES, IF A FLAME FROM A VEHICLE INTERIOR FIRE BECOMES LOCALLY DIRECTED AT THE NATURAL GAS FUEL TANK LOCATED IMMEDIATELY BEHIND THE REAR SEAT, THE FLAME COULD DAMAGE THE FIBERGLASS WRAP ON THE TANK WEAKENING THE TANK.

IF THE STRENGTH OF THE TANK IS SIGNIFICANTLY COMPROMISED, IT COULD RUPTURE, INCREASING THE RISK OF A FIRE.

DEALERS WILL INSTALL AN INSULATOR BEHIND THE CURRENT SEAT BACK. OWNER NOTIFICATION BEGAN ON JANUARY 7, 2004. OWNERS SHOULD CONTACT FORD AT 1-800-392-3673.

IN ORDER TO ENHANCE POLICE OFFICE SAFETY, MODEL YEAR 1992-2003 CROWN VICTORIA POLICE INTERCEPTOR (CVPI) VEHICLES WILL BE EQUIPPED WITH SHIELDS DESIGNED TO HELP PROTECT THE FUEL TANK IN HIGH-SPEED REAR-IMPACT CRASHES. FORD ALSO WILL BE OFFERING AN OPTIONAL TRUNK PACKAGE DESIGNED TO IMPROVE THE SAFE TRANSPORT OF SHARP-EDGED, HEAVY EQUIPMENT IN THESE VEHICLES.

SOME HIGH-SPEED REAR-IMPACT CRASHES HAVE RESULTED IN FUEL TANK PUNCTURES AND FIRES IN CVPI VEHICLES.

FORD HAS ADVISED US THAT SHIELD KITS HAVE BEEN AVAILABLE SINCE LATE OCTOBER AND WILL BE INSTALLED ON POLICE INTERCEPTOR VEHICLES AT NO COST. THE OPTIONAL TRANK PACKAGE WILL BE AVAILABLE BY THE END OF 2002. FORD HAS ESTABLISHED A NEW WEB SITE AT WWW.CVPI.COM TO ANSWER ADDITIONAL QUESTIONS ABOUT THE SAFE USE OF CPVI VEHICLES.

VEHICLE DESCRIPTION: PASSENGER AND SPORT UTILITY VEHICLES, PICKUP TRUCKS, AND MINIVANS. EQUIPPED WITH SEAT BELTS SUPPLIED BY TRW. IT IS POSSIBLE THAT THE DRIVER'S AND/OR FRONT PASSENGER'S OUTBOARD SEAT BELT BUCKLE MAY NOT FULLY LATCH. FORD CROWN VICTORIA BUILT AT ST. THOMAS ASSEMBLY PLANT FROM 4/17/00 - 5/29/01 MERCURY GRAND MARQUIS BUILT AT ST. THOMAS ASSEMBLY PLANT FROM 4/17/00 - 5/29/01. LINCOLN TOWN CARS BUILT AT WIXOM ASSEMBLY PLANT FROM 3/27/00 - 5/30/01. LINCOLN NAVIGATORS BUILT AT MICHIGAN TRUCK PLANT FROM 4/11/00 - 5/31/01. FORD WINDSTARS BUILT AT OAKVILLE ASSEMBLY PLANT FROM 3/23/00 - 5/30/01. FORD RANGERS BUILT AT TWIN CITIES PLANT FROM 3/28/00 - 5/30/01, AND ALSO AT THE EDISON PLANT FROM 3/13/00 - 5/25/01. FORD F-150 TRUCK BUILT AT NORFOLK PLANT FROM 4/18/00 - 5/25/00; AT ONTARIO PLANT FROM 5/10/00 - 5/28/01; AT KANSAS CITY PLANT FROM 9/11/99 - 5/25/01; AND AT CUAUTITLAN PLANT FROM 5/16/00 - 6/9/01. FORD SUPER DUTY F-250, F-350, F-450, AND F-550 TRUCKS BUILT AT KENTUCKY PLANT FROM 4/17/00 - 5/27/01; AND AT CUAUTITLAN PLANT FROM 5/16/00 - 6/19/01. FORD EXCURSIONS BUILT AT KENTUCKY PLANT FROM 4/17/00 - 10/2/00. FORD EXPEDITIONS BUILT AT MICHIGAN TRUCK PLANT FROM 4/11/00 - 5/31/01.

IN THE EVENT OF A CRASH, THE RESTRAINT SYSTEM MAY NOT PROVIDE ADEQUATE OCCUPANT PROTECTION, INCREASING THE RISK OF PERSONAL INJURY TO THE SEAT OCCUPANT.

DEALERS WILL INSPECT THE FRONT OUTBOARD SEAT BELT BUCKLES AND IF THE BUCKLE FAILS THE INSPECTION PROCESS, IT WILL BE REPLACED. OWNER NOTIFICATION BEGAN JULY 25, 2001. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT FORD AT 1-866-436-7332.

VEHICLE DESCRIPTION: MINIVANS AND PASSENGER VEHICLES. A RESTRAINT CONTROL MODULE (RCM) OR A SIDE OR FRONT CRASH SENSOR MAY HAVE BEEN ASSEMBLED WITH ONE OR MORE OF THE SCREWS THAT MOUNT THE CIRCUIT BOARD IN THE HOUSING MISSING. IF SOME OR ALL OF THE SCREWS ARE MISSING, THE PERFORMANCE OF THE OCCUPANT RESTRAINS COULD BE AFFECTED.

IN SOME CASES, LESS THAN THE INTENDED LEVEL OF PROTECTION IN THE EVENT OF A CRASH.

DEALERS WILL INSPECT THE RCM AND CRASH SENSORS AND, IF NECESSARY, REPLACE THEM.

CERTAIN PASSENGER VEHICLES, LIMOUSINES, AND MINI VANS WERE BUILT WITH A NEWLY DESIGNED RESTRAINT CONTROL MODULE (RCM). IN SOME CASES, THE RCM DOES NOT RECOGNIZE CERTAIN SYSTEM FAULTS THAT COULD RESULT IN AN AIR BAG OR SEAT BELT PRE-TENSIONER UNEXPECTEDLY ACTIVATING DURING THE SELF-TEST SEQUENCE AT VEHICLE START-UP.

THIS CONDITION COULD RESULT IN PERSONAL INJURY.

DEALERS WILL REPLACE THE RCM IN THESE VEHICLES. OWNER NOTIFICATION BEGAN SEPTEMBER 14, 2000. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT FORD AT 1-800-392-3673.