This is a very common problem to Ford vehicles with the 4.6 liter engine. In fact, there was even a class action lawsuit against Ford because of all the failures--but it's too late to get in on it.
The manifolds have an integrated coolant passage on the front of them which, on the older version, was all plastic and would melt or crack. On the new version it still cracks because, even though the upgraded Ford part has a mostly aluminum runner, it still mates to the head with plastic.
Dorman makes a replacement part 615-175 with a lifetime warranty so if it ever fails you can get another one for free. That's what I decided to install in this video. You can get that here:
www.amazon.com/Dorman-615-175-...
Actually Dorman makes two versions of this manifold. The 615-175 is for 2001 and up vehicles (not sure what the cut off date is) and the 615-178 is for older 1996-2000 models.
The vehicles affected by this failure are (sorry I seem to have lost my list of the various years for each model):
Ford Explorer
Ford Mustang GT
Ford Crown Victoria
Mercury Grand Marquis
Lincoln Town Car
Hope this helps everybody.
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