2004 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.

Ford Motor Company (Ford) is recalling certain model year 2003-2005 Ford Crown Victoria and Mercury Grand Marquis vehicles manufactured October 3, 2001, to August 2, 2005. The affected vehicles have a lighting control module (LCM) that may fail, resulting in a loss of headlights.

A loss of headlights can reduce driver visibility and increase the risk of a crash.

Ford will notify owners, and dealers will replace the LCM, free of charge. The recall began April 14, 2017. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 15S39.

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 POLICE INTERCEPTORS (CVPI) AND COMMERCIAL HEAVY DUTY (TAXI) VEHICLES, AT EXTREMELY HIGH OPERATING TEMPERATURES, THE SOUND INSULATING PANEL, LOCATED UNDER THE VEHICLE POSITIONED BETWEEN THE EXHAUST SYSTEM AND THE UNDERBODY, COULD SAG AND POSSIBLY CONTACT THE SURFACE OF THE CATALYTIC CONVERTER.

IF THIS OCCURS, THE INSULATOR MIGHT EXPERIENCE CHARRING OF THE OUTER LAYER, BURNING ODOR, OR SMOKE WHICH MAY ULTIMATELY RESULT IN A FIRE.

DEALERS WILL REMOVE THE EXISTING DASH INSULATOR AND INSTALL A REVISED DESIGN INSULATOR PAD FREE OF CHARGE. THE RECALL BEGAN ON JUNE 3, 2005. OWNERS MAY CONTACT FORD AT 1-800-392-3673.