Seven problems related to manifold/header/muffler/tail pipe have been reported for the 2015 Ford Explorer. The most recently reported issues are listed below. Please also check out the statistics and reliability analysis of the 2015 Ford Explorer based on all problems reported for the 2015 Explorer.
Both exhaust manifolds were cracked. Removed and drilled out broken studs and installed new converters. I heard a noise for a day or two and brought it in and they said this was the issue. I maintain my vehicle regularly at the Ford dealer and never indicated a problem. They said no recall but I googled it and I see many complaints with the same issue for my year, make and model.
There is a bad exhaust smell inside the cabin of the vehicle. Mostly when the hvac is on defrost. Upon inspection, there seems to be a cracked exhaust manifold. This smell happens the strongest when it's colder out, at idle, and while driving.
The contact owns a 2015 Ford Explorer. While driving various speeds, the contact felt nauseous, sleepy, and had headaches. There were no warning indicators illuminated in the vehicle. The vehicle was taken to future Ford Lincoln (650 automall dr, roseville, CA 95661, (888) 656-7577) and was serviced per Ford reference number: 17n03 regarding the carbon monoxide concern. The dealer repaired the plugs and rear hatch seals, used foiled patches on the plugs above the muffler, replaced the drain valve, and reprogrammed the hvac system. Upon driving the vehicle several days later, the contact still felt ill in the vehicle. The manufacturer was not notified. The failure mileage was 28,706.
My 2015 Ford Explorer limited started having problems 2 days after pulling out of the dealer. They have not stopped. Unfortunately, I waited too long for a lemon law claim. Most important problem: the smell of exhaust in my cabin under heavy acceleration, since day 1. It has been in 10 times since August 2015. The exhaust has been taken apart multiple times 1. "trans roll restrictor rubber hanging against exhaust pipe" was found. Replaced roll restrictor. Did something with TSB. 2. Returned for same smell: reprogram hvac module, replaced left rear air extractor, applied seem sealer to areas in TSB. Replaced grille and valve assembly. 3. Two months later, same thing - replaced grille and valve asy, reprogrammed hvac module, replaced air extractor 4. One month later: installed muffler asy; rvc code for TSB 1; replaced wheel lip molding,valve asy, dual rate air extractor still have the smell, but am always told they don't smell it. I had two people get sick and vomit in my truck because of the fumes in stop and go traffic. Additional problems: 1. Rear running lights did not work - twice at dealer to get repaired 2. Air bag light on constantly - wire assembly - TSB 16 was spliced 3. Awd off & abs lights constantly on - cost me $582 for them to take everything apart and check "pin fit" at all terminals. At which point the codes went away. 4. Driver-side outside door handle just broke off when I went to open the door - $149 5. When vehicle is put in park I get an error message vehicle not in park. I need a shift module, $395 plus tax and fees 6. Multiple other small problems. Vents not staying open, plastic covers coming off everywhere, speaker replaced twice my Explorer has been in the shop more times than I can count and Ford does not give loaner cars. I've been without a car for days at a time.
Carbon monoxide in cab. Experienced headaches and extreme fatigue. Had CO detector in car and spiked to 18 ppm and remained continuously. The vehicle is a squad car. Took vehicle to dealer and they found bad factory welds on exhaust manifold along firewall.
Exhaust smell in cabin after wide open throttle (wot) period onto highway. Exhaust smell in cabin in general during vehicle operation with heavy throttle. This is even after having the aformentioned repairs per Ford with the liftgate and rear seals area. See attached picture. I believe some of the leak may be due to lack of exhaust manifold bolts.
After a hard acceleration, on the highway or when accelerating on a freeway entrance ramp, we smelled a burnt hair odor in the passenger compartment of our 2015 Ford Explorer. After smelling this, I did some research and found other Ford Explorer owners with the same complaint and the smell was accompanied with carbon monxide. 9-28-15 dealership sealed rear underbody. 5-2-16 dealership installed new downturned muffler assembly. After this fix the smell went from a few seconds to a minute plus. Caused watering eyes, headache and coughing. 7-26-2016 dealership replaced the muffler system that had "bad welds", and reprogrammed electronic modules. Sept. 3, 2016 left on a trip, and the smell came back while paasssing on the freeway. Also on a trip, the burnt hair smell came into the vehicle through second row, passengers, lowered window. The smell appeared again while going up a hill on freeway, this time through the drivers lowered window. Watering eye, headaches and coughing accompanied the odor. 10-3-2016 dealership resealed all of the back of the vehicle and improved tailgate gasket. District engineer did an onsite inspection. 11-30-2016 picked the repaired vehicle up. 12-4-2016 exhaust fumes again while accelerating up freeway on ramp. 12-9-2016 Ford denied a buy back claim. The odor never happens around town. I need to get rid of this 2015 Ford Explorer for one we can take on the highway.