Omar Khalid
Plastic intake manifolds became popular in the 1990s due to their low weight and cost. However, early plastic intake manifolds were prone to failure as they couldn't withstand the under-hood heat and pressure. Ford was among the first automakers to adopt plastic intake manifolds, with their 4.6-liter V8 engines being some of the first to use this technology. Despite their flaws, plastic intake manifolds have seen significant improvements over the years, with modern versions featuring aluminum reinforcements and improved plastic composites that enhance strength and elasticity. While Ford settled class actions related to plastic manifolds in 2005 and discontinued the OEM intake manifolds in 2023, they continue to innovate with plastic composites, as evidenced by Henry Ford's enthusiasm for plastic-bodied cars in the 1940s.
| Characteristics | Values |
|---|---|
| Year of discontinuation of plastic intake manifolds | 2023 |
| Models with plastic intake manifolds | 1996-2002 model-year Ford, Lincoln, or Mercury vehicle equipped with a 4.6-liter, 2-valve V-8 engine |
| Reasons for discontinuation | Design flaws, failure to handle under-hood heat and pressure, cracks, leaks |
| Alternative materials | Cast iron, aluminum |
| Plastic intake manifolds' advantages | Lower weight and cost |
| Plastic composition | 35% fiberglass or related glass elements |
Explore related products
What You'll Learn
Plastic intake manifolds were prone to failure
Secondly, plastic intake manifolds were susceptible to cracking due to the nature of the material. The nylon-filled polymers used lack the strength of cast aluminum or iron intake manifolds and can easily crack due to mishandling, over-tightening fasteners, excessive bending, flexing, overheating, vibration, or an engine backfire.
Thirdly, plastic intake manifolds were unable to handle under-hood heat and pressure, which was not adequately factored in by car company engineers during the design process. This resulted in leaks and warpage under intense heat, which could eventually lead to cracks. Coolant that is old and deteriorated can also be corrosive to plastic, gradually eating away at the walls of the tubes carrying antifreeze inside the manifold.
Finally, dissimilar materials such as plastic, aluminum, and iron have different expansion and contraction rates as they change temperature. As a result, gaskets that provide a seal between an intake manifold and a metal cylinder head must be flexible and durable enough to withstand serious pulling and twisting forces. Early gaskets were not designed to do this, leading to leaks and warpage.
While plastic intake manifolds were prone to failure, it is important to note that modern replacements have corrected many of these issues. Today's plastic intake manifolds are made with engineered compounds that enhance strength and elasticity, making them more resistant to cracks and permanent warpage.
Plastic Weight Calculation: A Simple Formula
You may want to see also
Explore related products
Ford settled class actions over plastic manifolds in 2020
Plastic intake manifolds were introduced in the 1990s as a lower-cost and lighter-weight alternative to cast iron and aluminium manifolds. However, some of the first designs were flawed and prone to failure, with Ford being one of the manufacturers affected by this issue.
In 2020, Ford settled class actions over plastic manifolds, agreeing to replace or reimburse customers for composite manifolds alleged to be defective. The settlement covered an estimated 1.8 million vehicles and more than 2 million class members across the United States. This included owners and lessees of 1996-2002 model-year Ford, Lincoln, or Mercury vehicles equipped with a 4.6-liter, 2-valve V-8 engine and an all-composite air intake manifold.
The settlement offered reimbursement to those who had paid for repairs, with owners required to provide repair receipts to a Ford dealership for full reimbursement. Those without receipts could receive $735 if a dealership verified that the repairs had been made. The settlement also provided an extended retroactive warranty to cover fatigue cracks in the intake manifolds, which could cause coolant leaks.
While Ford did not admit guilt as part of the settlement, the agreement was expected to cost the company a significant amount in replacement costs and damages, with estimates ranging from $100 million to $370 million.
Plastic in the Body: What Stays and What Goes?
You may want to see also
Explore related products
Plastic intakes were replaced with plastic/aluminium alternatives
Plastic intake manifolds became popular in the 1990s as they were low cost and lightweight. However, they were prone to failure as they couldn't handle under-hood heat and pressure. This led to class actions against Ford, which covered 1.8 million vehicles in three states.
Ford has since discontinued OEM intake manifolds, with a redesigned 4.6 2V intake that features a metal coolant nipple to prevent cracked intakes. The new plastic intake manifolds are made from blends of plastic with 35% fiberglass or related glass elements, making them stronger and more elastic. This prevents permanent warpage and leaks.
Ford replaced the plastic intake manifolds with a plastic/aluminium combination. This was due to the advantages of aluminium, which is stronger and more resistant to heat and pressure. Aluminium was used in performance-focused cars before plastic intake manifolds became popular.
Today, modern replacements have corrected the issues of early plastic units, with plastic intake manifolds now featuring aluminium reinforcements, better seals, and heavier-duty construction with improved plastic composites.
Creating Plastic Textures in Maya: A Step-by-Step Guide
You may want to see also
Explore related products
Plastic intakes were popular in the 1990s
Plastic intake manifolds became popular in the 1990s due to their low weight and cost. Automakers began to manufacture plastic intake manifolds that were durable enough to survive initial testing. These plastic intakes were an improvement on the cast iron and aluminium manifolds used previously, as they offered the benefits of both without the drawbacks.
However, plastic intake manifolds were not without their issues. Early plastic manifolds were often flawed, with some prone to failure as they couldn't handle the under-hood heat and pressure. This was due to the manifolds being cast too thin without adequate reinforcement around external fittings. Plastic intakes were used in popular Ford models during this time, such as the 1996-2001 Mercury Grand Marquis, 1996-2001 Lincoln Town Car, and 1996-2001 Ford Crown Victoria.
Ford was aware of the issues with their plastic intake manifolds and took steps to address them. They offered extended warranty protection and "recall" programs for free replacements or repairs of defective intake manifolds as early as 1998. Despite these issues, plastic intake manifolds have continued to evolve and improve, with modern replacements correcting the design flaws of early plastic units. Today, plastic intake manifolds are made with blends of plastic and glass elements to enhance strength and elasticity, making them more reliable over long-term use.
Ford has continued to innovate with plastic components in their vehicles, with Henry Ford demonstrating the potential of plastic bodies for cars as early as the 1940s. While some of Ford's more recent vehicles, such as the Crown Victoria, have discontinued the use of OEM intake manifolds, the company's history with plastic intakes dates back to the 1990s when they first gained popularity.
Plastic Decomposition: The Long, Slow Process
You may want to see also
Explore related products
Plastic was used in Ford cars as early as 1941
The Soybean Car was designed to address the shortage of metal during World War II and to integrate industry with agriculture. Henry Ford also claimed that the plastic panels made the car safer than traditional steel cars and that it could even roll over without being crushed. To demonstrate the strength of the plastic, Ford swung an axe at a plastic panel on his personal car, showing that it could withstand the impact without a dent.
Ford's experiments with plastic car parts in the early 1940s were innovative for their time, but the plastic car idea eventually fell out of favour due to the challenges posed by World War II and the subsequent shift in focus towards war recovery efforts. Despite this, Ford continued to explore the use of plastic in automobiles, and plastic intake manifolds became popular in the 1990s due to their lower weight and cost compared to cast iron and aluminum alternatives. Today, automakers continue to use plastic intake manifolds, leveraging advancements in engineered compounds to enhance strength and elasticity, resulting in more durable and reliable plastic intake manifolds.
Primer on Plastic: Do You Need to Prime?
You may want to see also
Frequently asked questions
It is unclear when Ford stopped making plastic intakes, but it was reported in 2023 that Ford had discontinued the OEM intake manifolds.
Plastic intake manifolds were prone to failure because they couldn't handle under-hood heat and pressure.
Aluminum intake manifolds are an alternative to plastic intake manifolds.
