Manifold/header/muffler/tail Pipe problems of the 2016 Ford Explorer

The contact owns a 2016 Ford Explorer. The contact stated while driving at various speeds, there was an abnormally strong odor coming into the cabin of the vehicle. The contact stopped the vehicle and rolled the windows down. There was no warning light illuminated. The vehicle was taken to the dealer to be diagnosed. The contact was informed that carbon monoxide was leaking into the vehicle. After researching, the contact became aware that there were similar vehicles that were experiencing the same failure. The vehicle was not repaired. The manufacturer was contacted but provided no assistance; the contact was instead referred to the NHTSA for assistance. The approximate failure mileage was 98,000.

Tl- the contact owns a 2016 Ford Explorer. The contact stated that upon startup, the vehicle's engine would rumble and shake as the check engine light would illuminate. The contact also stated that at various rates of speed, the vehicle would stall while depressing the accelerator. The tail pipe would also emit an excessive amount of smoke while the vehicle was in operation. The contact had taken the vehicle to three different independent mechanics. On his first visit, the contact was made aware that coolant had been leaking through the engine's head gasket. The second mechanic was unable to diagnose the vehicle and after the third visit, the contact had the sparks plugs and the boots replaced; however, the failure continued. The manufacturer was notified of the failure and referred him to NHTSA. The failure mileage was approximately 91,000. Jo.

The vacuum tube assembly/ hoses corroded to the point the braking system was compromised. The dealership's assessment states that battery acid spilled onto the hose and the acid ate though it. When I visually inspected the hose, the only part of the hose that was corroded where both ends where it connects to the manifold and other end. I find it very odd that batter acid will only spill on 2 opposite ends of a hose, which happens to be where the connections are. The battery was replaced after the original battery's core exploded.

Strong exhaust and very high levels of CO entering cabin at normal acceleration, very bad at hard acceleration I have multiple pictures of my CO sensor I had in the vehicle for some time now with lethal CO levels. I believe the exhaust manifolds have big enough cracks to flood in CO into the cabin through openings. Mine has had the 'dealer itsb' to resolve, no change and it registered higher after. Replace this manifold and seal this truck or buy it back from me Ford. If putting my family's life in danger daily doesn't scare you, the pictures and proof I have are enough for another lawsuit against you for this! I need to be contacted by a Ford rep (not a dealership) to resolve or my lawyers will follow up with you. -john cook dallas, GA 2016 Explorer limited 3. 5 na.

2016 Ford Explorer XLT v6 ti-vct flex fuel vehicle (ffv). Exhaust enters cabin during acceleration. Putrid odor of exhaust resembles a foul blend of vomit, rotten eggs, burnt hair, burnt wax. Headache and horrible smell lingers in sinuses continues to day following exposure. Stench is much worse under heavy acceleration and/or driving uphill with rear a/c on high fan speed. Ford service acknowledged wide-spread problem performed TSB 17-0044 sealing underbody seams, reprograming rear a/c and replacing exhaust components. TSB 17-0044 is ineffective and problem persists. 1. Ford has not isolated source of excessive carbon monoxide (CO), hydrocarbons (hcs) and nitrogen oxides (nox). Is engine deflection under acceleration impacting exhaust manifolds causing leakage in pipe joints? is rich fuel mixture in engine with unburned fuel producing elevated catalytic temperatures damaging manifolds or joints? are ffv engines fitted with undersized or faulty catalytic converters? 2. Exhaust system fails to expel exhaust away from vehicle. Ford acknowledges as evidenced by TSB 17-0044 replacing mufflers and exhaust tips. 3. Exhaust gasses pool in bumper cover and numerous cavities under body. 4. Air conditioning system fans actively pull exhaust into the vehicle likely through air extractor vents in quarter panels. Ford acknowledges as evidenced by TSB 17-0044 replacing air extractor vents and reprogramming rear a/c to slow or halt fans under various braking scenarios. Ford misrepresenting elevated CO levels only found in police interceptors. After Ford service sealed seams per TSB 17-0044, I detected 17 ppm of CO in two detectors. Ford must evaluate every exhaust component under loading for deflection and excessive heat. Can exhaust enter via mid body, engine compartment or cowl in addition to rear of vehicle? pics illustrate rear infiltration.

Ford Explorer cabin has a bad exhaust type smell. Vehicle was purchased used in December 2016. Smell was more evident in March to July when we ran the air conditioner more. When we accelerated to highway speed the smell would follow a few seconds later. This was experienced by several people on many occasions. This is my wife's daily driver. Toward the end of may 2017 she began complaining daily of dizziness and headaches. The smell was still present after accelerating. We took the car in to a local Ford dealer on June 13. They performed the recommended repair per the Ford bulletin TSB 170044. We took the car from the dealership on June 22 and still smelled the bad smell that evening. Returned the car to the dealer the next day (June 23). They then replaced the majority of the muffler and tail pipe assembly. Car was picked up on July 7 and driven that evening. Smell was still noticeable in the cabin. Went to another Ford dealer the next day to discuss the problem and they recommended we talk to the service director at the first Ford dealership and give them one more chance to fix the problem. Third trip to the same dealer with the same problem. They said they inspected all of the previous work and test drove the car and found no problems. The service director also told us we could not prove there was any exhaust fumes or carbon monoxide inside the cabin. (I told him he could not prove that there was not any exhaust fumes or CO in the cabin). Car still has a bad odor in the cabin when accelerating to highway speed with the air conditioner running. (the smell may be less but is still noticeable). We have ordered a battery operated continuously monitoring carbon monoxide detector to put in the car. We have not installed it yet, but we can let you know when we do and any results. Wifes dizziness and headaches went away while the Explorer was in the shop.

We took our 2016 Explorer limited back to the shop for the second time after smelling exhaust in the cabin again while in operation. During the first visit the dealer began discussing the Ford repair bulletin that came out 30 days or so ago that was to fix the exhaust leak. However, after a couple of hours later we received a call that the bulletin he referenced was specifically for 2011 thru 2015". We were told that per the bulletin the exhaust system from the engine manifold to the tail pipe gets replaced, a fresh air vent near the rear of the vehicle gets "re-routed" and the bumper comes off to gain access to some metal seams needed to be filled. Our service representative stated his hands were tied and could not do anything more than take it in a check it out. They called a found the exhaust outlets were recessed too far into the bumper and reset them to the original position. We picked it up Monday and then driving it Tuesday this week a horrible smell came tor the cabin and took my breath away. Black smoke was coming out of the exhaust pipe. We took it back to the dealer yesterday.