Air Conditioner problems of the 2016 Ford Explorer

The entire air conditioning system has corrosion and rusted completely out. This vehicle is only 4 years old. It should not be rusted beyond repair. This entire system is very costly. There is a leak at the rear evaporator housing connection.

Carbon monoxide in car. I drive up to 8 hours a day fro my job. Over the past several months I've experience dizziness and nausea thought out the day and recently learned of CO issues with Ford Explorers. I purchased a CO detector last week to test my car over the past 3 days the alarm has gone off indicating high levels of CO in the cabin while the car was in motion and stopped. Specifically, with the air conditioner on "auto" at approximately 3500rpm the detector registered CO in the cabin, at 4500 rpm the level of CO doubled.

My 2016 Ford Explorer cabin has been filling with CO I purchased a CO detector a month ago after feeling sick while driving on multiple occasions. Today the CO detector read 15 with no air on. Yesterday it read 18 with air conditioning on. I feel this could be dangerous to people who don't know about CO poisoning symptoms. Please help me with this.

Case number is 1095836. I again experienced carbon monoxide in my 2016 Ford Explorer cabin. Once on September 3, 2017 on a downhill path on a rural rod in the mountains above santa fe, nm with the air conditioner on, but not on recirculate mode and again in santa fe on a city street on September 8, 2017 with the air conditioner on. Both times I was driving at 20 - 30 mph. I have a carbon monoxide detector installed in the third row of the Explorer which set off an alarm. I immediately turned off the a/c and opened the windows. The alarm turned itself off almost immediately. I did not notice any exhaust fumes. The first time I was in a line of traffic with 3 - 4 car lengths between the car that I was following. The second time there was no traffic ahead of me on the city street.

Since we have purchased the vehicle we have smelled a rotten egg/burnt hair smell from the vehicle. It is at its most potent point when accelerating to higher rates of speed. It keeps a fairly consistent smell at speeds of 65 mph and higher as well. The smell always seems to come from the air conditioning vents. Is it also coincidental that the cabin air filter already needs to be replaced? this has made for disorienting and nauseating trips in the vehicle for all passengers. Our child has complained and has felt ill when riding in his car seat in the second row. On a recent 6500 mile road trip, I became severely ill and had difficulty breathing while riding in the truck. I was nauseated for several hours afterwards and had an excruciating headache. We discussed this with the location we purchased the vehicle and they stated there is nothing they can do about it. We then took it to another location in cabot, arkansas and again; nothing can be done about it. We were told that Ford is aware of the issue and it has been going on for several years now. Why were we not warned of this issue? we are putting our health and my child's health on the line every time we drive the truck but due to our finances, we have no choice but to keep the vehicle.

Whenever you accelerate quickly or put the engine under strain (such as going up a hill) and the air conditioning is on and recycle mode is engaged you get a strong exhaust odor into the cabin. The vehicle has been back to the dealership to fix this problem but the fix has not worked.

Carbon monoxide: I have been smelling an exhaust like smell in my car since I purchased it brand new. For awhile, I assumed it was new car chemicals burning off from the engine etc. However, over time I still was presented with this odor. My husband and I bought a carbon monoxide detector to see if any dangerous fumes were presenting inside the car. Upon my quick 6-7 minute drive to church the carbon monoxide levels read 6ppm. When driven later by my husband for about 15 minutes at a slightly faster speed, it climbed to 12ppm! we had the air conditioner on and the recirculating air on. When we held the carbon monoxide detector up to the air conditioner, the numbers climbed faster. I have a photo of the 6ppm, but my husband didn't have his phone and couldn't take a picture of the 12ppm at the time. He will try to get a one soon. This car is the primary vehicle for my three and one year old children. We will no longer be using this vehicle risking their safety.

Exhaust smell when running the rear air conditioning system. Seems to occur when at higher rates of speed, 60+ mph with rpm 3k+. Exhaust smell is isolated to the rear ac system when recycled air is turned on. The last test we did was on a highway, going uphill.

There is an exhaust smell permeating the cabin in city driving causing dizziness and the cabin gets flooded with exhaust fumes under heavy acceleration due to merging into traffic on interstate on ramps or while passing in any driving condition all contributing to dizziness, headaches and sometimes nausea. Even with the air conditioner on and the recirculating air feature engaged. Several times during my drive I need to open the window to air out my vehicle to avoid becoming ill. I've had it to the dealer several times with no resolution of this issue and Ford's reply is sorry but you experience no more than what is acceptable levels of exhaust fumes. This is the first vehicle I've owned that floods the cabin with exhaust fumes even with the a/c recirculating the air. This is an ongoing issue since I've owned the vehicle February 2017.

Every time I accelerate and the air conditioner is on recycled air, there is a heavy rotten egg/sulfur smell. . . Like exhaust. Believe that the exhaust (carbon monoxide) is coming into the vehicle. I understand I am not the only one that has this problem. I purchased this vehicle brand new in may 2016, and have complained to the dealership, but they don't find a problem. It has happened ever since I purchased the vehicle. I am beginning to wonder if this is causing me to have a hard time breathing at times. Hoping this will fall under a recall soon and it can get fixed.

There is a heavy smell of trash/rotten eggs that started in November 2016 in my 2016 Explorer with 35,xxx miles on it. The local dealership told me I needed to pay out of pocket ($140. 00/hour) for them to search for a "dead animal". Even though it there was absolutely no signs of animal droppings or chewing. They asked that I return the rental car. My Explorer was returned to me with no odor (car was not running for days). That would tell you right there that it isn't an animal. Why would the smell go away completely if the dead animal was just in there 24-hours before? the minute the air conditioning was turned on the odor was back. Over the winter there was only an odor when using the automatic start (default to turn on defrost). Now that we are having warmer weather the smell is back in full force with the air conditioning. I have an appointment at another dealer for March. It is now out of the manufacturer warranty (40,xxx miles). Such a disappointment. I sent an email to Ford directly with absolutely no response in November.

When a strain is put on the engine, such as in passing gear, a burning rubber smell is emitted in the interior, even with the air conditioning in recirculate air in vehicle mode. In 2013 I dialogued with Ford headquarters about this same issue with a 2012 Explorer limited that I owned. In 2013 they sent me to royal oak Ford in royal oak. Mi and the service manager rode with me to observe the smell. They never offered any type of repair. I was hoping they would have solved this by 2016, however now with the warm summer weather this 2016 Explorer emits the putrid smell just as badly. It smell like the rubber padding on top of the engine is burning. Vehicle has 8,900 miles, purchased brand new 10/25/15.

( I am experiencing with my 2016 Ford) I began having trouble with exhaust leak in air condition however dealer was not able to repair due to Ford has not issued any manuals how to fix this particular problem and dealer advised there is nothing they can do. This problem creates a serious safety hazard.

I am having fume leakage into the cabin of my vehicle. I took my vehicle in to dahl Ford -la crosse and they had the vehicle for over 2 weeks. When I called the tech person told me they were waiting for parts to fix my vehicle and that there was a leak into the cabin. After another week went by without any word I called and they said nothing was wrong with my vehicle. I went into see the dept manager and he said there was never anything wrong with the vehicle. When I asked him who was lying him or the tech person he did not reply. They said they had the local fire department test the vehicle for carbon monoxide but they did not list under what conditions it was tested at. I had my own carbon monoxide tester in the vehicle and it was registering carbon monoxide. I left very upset as I have been sick after I drive in the vehicle. They won't let me out of my lease either and won't do anything to fix. I left very upset. The fumes occur when sitting idle and air conditioner on and when moving, air conditioner on and accelerating. I sent a letter to Ford corporate explaining this in September 2016 and have not heard a word back.