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Ford's 3.8-Liter V-6 Head Gasket Problem - Straight Talk
By Neil G. Chirico
Last updated: 2001-04-17
Thanks to Edmunds.com Town Hall visitors, we knew the Ford 3.8-liter engine head gasket problem was a hot topic laced with confusion about what Ford is offering to past and current owners. We figured a few points could use some clarifying, so we did some research to separate fact from fiction. We made several calls to Ford Motor Company and got in contact with Mike Vaughn, Public Affairs Manager - Service Programs. Mike was very helpful in answering our questions and sending material to help sort through this confusing topic.
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Programs, Recalls, Warranty Extensions... Huh?
Before we explain the different programs Ford currently does or previously has offered for the 3.8-liter engine head gasket problem, first let us explain the difference between an owner notification program, a recall, and a warranty extension. The manufacturer, on a completely voluntary basis, may conduct an owner notification program. Programs typically have a mileage and/or time restriction, which can expire without being, or even needing to be, completed. Recalls are conducted with the government and are not closed until they are completed. There are two types of recalls, for either safety- or emissions-related repairs. The last type of service notification would be a warranty extension, which is just that: an extension of a part or whole of the vehicle's warranty. In any of these service notifications, it does not matter if you are the original owner or if you purchased the vehicle used; the service notifications go with the vehicle and not with the owner. You may check at any Ford dealer with your VIN (vehicle identification number) to see if your vehicle has any open service notifications or on-line at
www.ownerconnection.com.
Where did it all go wrong?
For the 1994 model year Ford made several changes that affected the performance of the 3.8-liter V6's cooling system. Those changes included:
Water pump design - front-wheel-drive models only
Cooling system flow - parallel versus series - front-wheel-drive models only
Head bolt run-down specification - front- and rear-wheel-drive models
Head bolt design/configuration - rear-wheel-drive models
A/C refrigerant change from R12 to R134a - front- and rear-wheel-drive models It was a combination of all of these items that contributed to the main concern, which was an increased rate of head gasket failures on both front- and rear-wheel-drive vehicles for the 1994 and 1995 model years. Front-wheel-drive vehicles are more likely to be affected due to the differences in cooling system flow patterns versus the rear-wheel-drive vehicles. Ford states the affected vehicles number 717,680 front-wheel-drive models and 294,434 rear-wheel-drive models.
Now let's look at the changes Ford made for the 1996 model year in an effort to correct the problem:
Cooling system flow - change to series flow - front-wheel-drive models only
Heat-treating the cylinder heads - front- and rear-wheel-drive models
Head gasket design - heavier bore grommet and rebalanced face and bore grommet loads - front- and rear-wheel-drive models In 1997 one more improvement was made:
Head gasket design - multi-layer steel head gasket - front- and rear-wheel-models. The head gasket used since 1997 represents new technology not available when the 1994/95 head gaskets were developed. The current service replacement gaskets are also different, with higher-density carbon and/or graphite, and are a denser gasket with heavier bore grommets. Front- and rear-wheel-drive gaskets are not interchangeable due to differences in coolant passages.
And now... on with the program!
Now that you understand what occurred and what corrections Ford has made over the intervening years to correct the situation, let's look at what Ford has offered previously and what programs are currently available. The first program Ford offered was in 1998, titled 98M01, and was issued for the following vehicles:
1994 Lincoln Continental
1994/95 Ford Taurus/Mercury Sable
1995 Ford Windstar This program offered additional warranty coverage at no charge to the customer on premature failure of the head gasket. The coverage period was for five years or 60,000 miles, whichever occurred first, for the Ford products, and six years or 75,000 miles, whichever occurred first, on the Lincoln Continental.
Next came program 00M09, which basically extended the original program from five years or 60,000 miles to seven years or 100,000 miles, whichever occurred first, covering the same vehicles as the 98M01 program. Letters to consumers for this program went out in March of 2000. Ford obtains a current list of owners from R.L. Polk and several other sources.
The latest program is 00M10, which adds rear-wheel-drive vehicles to the mix and includes:
1994/95 Ford Mustang and Thunderbird
1994/95 Mercury Cougar
This program has the same seven years or 100,000 miles, whichever occurs first, coverage as the front-wheel-drive counterparts. Letters for this program were sent to consumers in May 2000.
A grace period for 1994 vehicles has been extended to October 1, 2000 or 100,000 miles, whichever occurs first, since some of these vehicles are over seven years old.
The solution to your situation...
If you own one of the affected vehicles, there are several solutions that Ford offers. The first is a refund for out-of-pocket cost on a previous repair, even if you don't currently own the vehicle. What Ford requires is a receipt for the out-of-pocket costs, even if the repairs were completed by an outside source other than the dealer. An alternative is, instead of a refund from Ford for your out-of-pocket costs, a certificate for $4000 toward the purchase of a new Ford, Lincoln, or Mercury vehicle can be issued. You have a six-month time frame from the date when the letters were sent out to respond to the $4000 offer. You may still be reimbursed for out-of-pocket expenses after this six-month time period; just the certificate portion of the offer has the six-month limit. The certificate you receive is good for six months from the time it is issued to you. The certificates are sent to the dealer to whom you turned in your previous repair receipts to. You may turn your receipts into any Ford, Lincoln, or Mercury dealer in the United States. The certificates sent to the dealers are accompanied by a copy of the notification letter from Ford to the consumer, letting the consumer know the certificate has been sent and will be waiting for them at the dealer. The certificate can be used at any Ford, Lincoln, or Mercury dealer within the six-month time frame. The certificate may be used in addition to any Ford incentives offered at the time such as rebates and/or special finance rates.
The second remedy is if you have a total engine failure, and the dealer cannot get delivery of an engine within five business days, Ford will offer a buy out of your vehicle at the current NADA wholesale value of your vehicle, plus a $3,000 certificate towards the purchase of a new Ford, Lincoln or Mercury vehicle. Again, the certificate is valid for six months from the time issued. This offer is current within the constraints of the program's time and/or mileage period.
Of course let's not forget that you still have the extended coverage until the seven years or 100,000 miles, whichever occurs first, from the original vehicle warranty start date from Ford.
Clearly Ford is trying to rectify a delicate situation with its customers and deserves commendation for its extraordinary efforts to take care of the customer. We hope this answers some of the questions Town Hall users have posed, and helps you in your quest to get your Ford 3.8-liter engine head gasket situation resolved.