What new car is built well, with metal parts?

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Texas Republic
Is there any new gas/hybrid car (not truck) for 2025 MY that is actually built to last?

Requirements:
  • Metal intake manifold
  • Metal valve cover
  • Metal thermostat
  • Metal oil filter housing
  • Metal oil pan
A few short years ago, most cars would be on this list but I wonder if there is at least one new car now.
 
I do think some metal components contribute to longevity. A lot of plastic components get brittle over time. There is a coolant tee that is famous for getting brittle and breaking and overheating engines in the w140 chassis Mercedes. There is a factory metal replacement. On the other hand there can be corrosion and rust associated with metal components. I know a lot of metal oil pans and gas tanks have been replaced due too rust. I’ve never heard of a plastic fuel tank having issues.
 
I know why your asking - but I think the answer is mostly no - probably for technical reasons.

Intake - no way they could build the complexity of modern intakes into a cast piece. If there done right they don't cause issues

Valve covers - the injection molded ones incorporate the spark plug tube seals directly. Again, would be very expensive to do with stamped steel, and likely wouldn't be as good.

Thermostat - this one I agree with you, but given most OEM's now incorporate a sensor directly into the housing, I think this is here to stay.

Oil filter - the new Toyota Dynamic force 4 cylinders have a traditional can type oil filter screw on mount on the bottom of the engine - so this is still available.

Oil pan - I 100% agree with this. Many cars still have this - again my Toyota does. For some vehicles an aftermarket replacement option is available if they come with plastic. Some are easy to change. Some not so much.
 
Is there any new gas/hybrid car (not truck) for 2025 MY that is actually built to last?

Requirements:
  • Metal intake manifold
  • Metal valve cover
  • Metal thermostat
  • Metal oil filter housing
  • Metal oil pan
A few short years ago, most cars would be on this list but I wonder if there is at least one new car now.
I can say the thermostat housing is aluminum on my f150. intake, valve cover and oil pan are plastic. asterisk for the oil pan, its actually a composite with fiberglass fibers embedded in it.
 
I don't understand the whole issue with plastic cover or parts that only see air. plastic intakes, valve covers and even oil/transmission pans. they have been used for a while now, and with some exceptions its relatively successful.
I am OK with plastic intakes and valve covers.

Plastic oil pans maybe - if there completely protected by the sub frame or something - but most are at least partially exposed. Platic doesn't bend it cracks.

Plastic coolant elbows and thermostat housings are a failure waiting to happen due to so many hot / cold cycles. The good news is there usually easy to change - so at 8 or 10 years just change all the parts.
 
Is there any new gas/hybrid car (not truck) for 2025 MY that is actually built to last?

Requirements:
  • Metal intake manifold
  • Metal valve cover
  • Metal thermostat
  • Metal oil filter housing
  • Metal oil pan
A few short years ago, most cars would be on this list but I wonder if there is at least one new car now.
You happen to pick five components out of what, 10,000, and think that you’ve got a measurable difference in longevity?

Those aren’t very high failure rate components. What about the rust proofing on the vehicle? what about the driveline longevity? What about those engines that have machining debris in them?

Further, even if the .001% of the car’s components on which you are focused are made of plastic, why do you think they don’t last?

My wife’s Volvo has over 300,000 miles on it. It has a composite (plastic) oil filter housing. That housing has been off and back on over 50 times, roughly speaking.

And it is still fine. So, you have listed five components, that you think don’t last when they’re made of plastic, and yet my experience is those components last at least 300,000 miles, and 22 years.

So, I think you would want them to build the entire car as well as they built that “plastic” oil filter housing!
 
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I don't understand the whole issue with plastic cover or parts that only see air. plastic intakes, valve covers and even oil/transmission pans. they have been used for a while now, and with some exceptions its relatively successful.
They do seem to last warranty periods, but if replacing I'd want something that isn't going to crack.
 
Trans Am has a "Plastic" intake and I guarantee it has had enough nitrous run through it to blow all your cars into the stratosphere. :)

The material is not the issue. My 3800s have plastic valve covers. No issues. My TBI 350's and 454 always had metal thermostat housing that leaked because they would warp. I have a 2005 Ford 500 sitting outside with 210,000 miles on it original plastic impeller water pump and plastic thermostat housing/coolant T. Environment and correct regular maintenance is bigger factor on MOST vehicles.
 
Absolutely none of those parts being made out of "metal" will contribute to longevity.
Utter nonsense. I've seen failures of all the listed (and other) plastic parts that would not happen with metal (aluminum, steel). Example1: I owned a BMW. Plastic thermostat cracked. Example2: Brother's Honda plastic valve cover warped. On my 3 cars (20+ year old), all the listed parts are made from various metals and all are original.
Thank you for sticking to the topic! I suspected so but wanted to ask just in case there was still a unicorn out there.
I know a lot of metal oil pans and gas tanks have been replaced due too rust. I’ve never heard of a plastic fuel tank having issues.
Rust/corrosion is a non-issue here in TX but heat certainly is. Plastic tanks are OK, I didn't list that as an item.
Intake - no way they could build the complexity of modern intakes into a cast piece. If there done right they don't cause issues

Valve covers - the injection molded ones incorporate the spark plug tube seals directly. Again, would be very expensive to do with stamped steel, and likely wouldn't be as good.

Thermostat - this one I agree with you, but given most OEM's now incorporate a sensor directly into the housing, I think this is here to stay.
Oil filter - the new Toyota Dynamic force 4 cylinders have a traditional can type oil filter screw on mount on the bottom of the engine - so this is still available.
Oil pan - I 100% agree with this. Many cars still have this - again my Toyota does. For some vehicles an aftermarket replacement option is available if they come with plastic. Some are easy to change. Some not so much.
The Toyota 2ZZ-GE engine in my two Vibe GTs is plenty complicated and the intake is all aluminum. It can be done. Valve cover also aluminum. Will last forever. Agree with the rest!
I don't understand the whole issue with plastic cover or parts that only see air. plastic intakes, valve covers and even oil/transmission pans. they have been used for a while now, and with some exceptions its relatively successful.
The main issue is heat cycling and tendency of plastics to degrade with time, not chemical breakdown due to contact with fluids. That said, none of the parts listed "only see air." All see oil and/or fuel due to their location, EGR and EVAP systems.
You happen to pick five components out of what, 10,000, and think that you’ve got a measurable difference in longevity?
Of said components, absolutely!
Those aren’t very high failure rate components. What about the rust proofing on the vehicle? what about the driveline longevity? What about those engines that have machining debris in them?
Yes they are. There are many other things to consider, of course, but that's not what this post is about. This post is specifically about use of plastic/metal in those components.
Further, even if the .001% of the car’s components on which you are focused are made of plastic, why do you think they don’t last?
Personal experience. Plastic warps and/or crack with age and use due to heat cycling. I've seen all these components fail when made of plastic on various cars (obviously not all at once) but rarely/never when they're metal.
My wife’s Volvo has over 300,000 miles on it. It has a composite (plastic) oil filter housing. That housing has been off and back on over 50 times, roughly speaking.
Cool, so you're the 1, congrats on winning the lottery. Anecdotal and lucky. All the listed components in all 3 of my current cars are made from metal and all are original with zero failures.
 
Cool, so you're the 1, congrats on winning the lottery.
Housing or cap? I had a VW and a Camry and both had a plastic oil filter housing. VW did over 300k, at least 25 changes, no problem. The Camry did 230k and similar 30 changes. My Tundra had same cap, no idea but it was fine at 170k when traded.

In this area I am more concerned about the parts made from metal! rust holes or seizing.
 
The Toyota 2ZZ-GE engine in my two Vibe GTs is plenty complicated and the intake is all aluminum. It can be done. Valve cover also aluminum. Will last forever. Agree with the rest!
No, its underpowered for its size and likely wouldn't meet Cafe standards today. It was obsoleted in 2008 for a reason - that is exactly the year that Cafe started really ramping up.
 
Utter nonsense. I've seen failures of all the listed (and other) plastic parts that would not happen with metal (aluminum, steel). Example1: I owned a BMW. Plastic thermostat cracked. Example2: Brother's Honda plastic valve cover warped. On my 3 cars (20+ year old), all the listed parts are made from various metals and all are original.

Thank you for sticking to the topic! I suspected so but wanted to ask just in case there was still a unicorn out there.

Rust/corrosion is a non-issue here in TX but heat certainly is. Plastic tanks are OK, I didn't list that as an item.

The Toyota 2ZZ-GE engine in my two Vibe GTs is plenty complicated and the intake is all aluminum. It can be done. Valve cover also aluminum. Will last forever. Agree with the rest!

The main issue is heat cycling and tendency of plastics to degrade with time, not chemical breakdown due to contact with fluids. That said, none of the parts listed "only see air." All see oil and/or fuel due to their location, EGR and EVAP systems.

Of said components, absolutely!

Yes they are. There are many other things to consider, of course, but that's not what this post is about. This post is specifically about use of plastic/metal in those components.

Personal experience. Plastic warps and/or crack with age and use due to heat cycling. I've seen all these components fail when made of plastic on various cars (obviously not all at once) but rarely/never when they're metal.

Cool, so you're the 1, congrats on winning the lottery. Anecdotal and lucky. All the listed components in all 3 of my current cars are made from metal and all are original with zero failures.
Let’s back up a bit.

You’re stuck on “plastic bad, metal good”.

It’s not that simple. I offered one example, but 7 of my cars have a “plastic” oil filter housing. All are working well. So, the anecdotal rebuttal of 3 cars is just as anecdotal as you claim my experience to be.

But I am not the “one”.

“Plastic bad” is a gross oversimplification, and a specious stereotype.

The center fuselage of this airplane is “plastic”. It handles salt water, carrier landings, catapult launches, over 7.5 times the force of gravity and combat conditions. With millions of hours of flight time on the fleet of over 1,000 Hornets built, there has not been one failure of the “Plastic”.

IMG_0442.webp


“Plastic” was chosen for lighter weight, better corrosion resistance, simpler manufacturing of complex shapes and structure.

Plastic - in a word - is good.
 
I can maybe get behind some of these ideas. Most not:

1. Metal intake manifold: If coolant run through them, maybe. However, most manifolds are "dry" now and simply flow air and PCV gases. These smooth wall plastic manifolds simply perform much better. They are much better shaped, flow much better than their metal counterparts, do not heat soak, and do not coke or collect PCV crud like their metal counterparts. I like plastic here.

2. Metal valve cover: Sure. Indifferent about this one. No significant failures for either, in my experience.

3. Metal thermostat (housing, I assume?): I don't miss leaky thermostat housings because they are corroded/pitted beyond cleaning up, which was pretty standard fare for all engines eventually as they aged. Failure rate is pretty low on plastic, in my experience.

4. Metal oil filter housing: yes.

5. Metal oil pan: yes.


To answer the original question: None. Things have evolved from the old ways. To get what you're looking for, you'd have to buy something approximately 1990 - older.
 
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While I agree that metal components can last longer than plastic(if they don't rust or corrode) if you want to keep something for decades. I do think lots of plastic car components will probably not be good in 40-50+ years from now and will make having a 2020 Elantra a big PITA to keep as a show car in 2100.
I think a more useful topic for keeping 20-30 yr old daily drivers on the road, is which manufacturers cheap out on their plastic...

So far all the black plastic important stuff under the hood of my Focus is still good, some of the little clips, and retainers are getting brittler, but I don't tend to break them if I use some care. Almost any color plastic that is not black is not good, like the pcv hose retention clip, but a carefully bent piece of metal wire replaced it fairly easily, some of the electrical connectors have the tabs broken from being brittle, but they seem to hold tight without them. The plastic expansion tank, power steering reservoir, and brake/clutch reservoir are discoloring, but seem good so far.
The thermostat comes with a new plastic housing and the T for the heater seems OK. I'm having problems with the spring clips rusting and breaking.
 
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While I agree that metal components can last longer than plastic(if they don't rust or corrode) if you want to keep something for decades. I do think lots of plastic car components will probably not be good in 40-50+ years from now and will make having a 2020 Elantra a big PITA to keep as a show car in 2100.
If you can get the stp file, my kid can print you a new plastic part.

Try that with cast aluminum.
 
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