Has anyone heard of coolant melting the overflow bottle? The car doesn't overheat according to the gage but it seems to be too hot for the bottle. Are the bottles defective?

Why do you think the coolant is melting the coolant overflow tank. Is it actually deformed, or just leaking? There is no way the coolant should be so hot that it melts the bottle without the engine severely overheating.

-Rod

Shorod,
The bottle has a soft area beside the inlet tube on the rounded part and there's a pin hole in the middle of it.
http://smg.photobucket.com/albums/v423/classicboater/th_Taurus.jpg

I cannot get a good view of the problem spot from the included photo, but it doesn't appear to be deformed. Maybe the mold for your particular bottle had a spot where the plastic injection didn't flow completely? Other than the hole, does the bottle look different than it did a few weeks ago?

-Rod

The soft spot is right beside the clamp on the inlet tube to the right of the light reflection.

Do you have hot air coming out of the tank when the engine is cold?