Catalytic Convertor Problems of Ford Explorer

The contact owns a 2022 Ford Explorer. The contact stated that upon starting the vehicle, the check engine warning light illuminated and remained illuminated. Additionally, there was an abnormal rattling sound coming from the front end of the vehicle, and there was an abnormal gasoline odor inside the cabin of the vehicle. The vehicle was taken to a local independent mechanic to be diagnosed, and the contact was informed that the catalytic converter was faulty and needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure. The approximate failure mileage was 72,378.

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The contact owns a 2020 Ford Explorer. The contact stated while driving 40 mph, there was an abnormally loud sound coming the rear end of the vehicle. No warning light was illuminated. The contact returned to the residence and inspected underneath the vehicle and became aware that the right exhaust had detached. The vehicle was taken to a dealer where it was diagnosed and determined that right exhaust needed to be replaced. The vehicle was not repaired. The contact related the failure to customer satisfaction program: 21b35 (right-hand catalytic converter and right-hand and left-hand exhaust flexible pipe(s) inspection); however, the VIN was not included in the customer satisfaction program. The manufacturer was notified of the failure but provided no assistance. The contact was referred to the NHTSA hotline for assistance. The failure mileage was 40,416.

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The contact owns a 2021 Ford Explorer. The contact stated that while his wife was driving at an undisclosed speed, the driver heard an abnormal sound coming from the rear of the vehicle. The contact stated that the failure recurred while the vehicle was idle. Additionally, the contact stated that the driver had noticed an abnormal exhaust odor coming from the outside of the vehicle. The vehicle was taken to the dealer, where it was diagnosed that the catalytic converter had fractured at the welds location and needed to be replaced. The vehicle was not repaired due to cost. The vehicle was then taken to an exhaust system center, where it was being diagnosed. The vehicle was not repaired. The contact related the failure to Ford campaign number: 21e11. The manufacturer was not made aware of the failure. The failure mileage was approximately 89,000.

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The contact owns a 2020 Ford Explorer. The contact stated that while operating the vehicle, exhaust fumes were present inside the cabin of the vehicle and an excessively loud exhaust sound was coming from the exhaust system. The vehicle was taken to the local mechanic to be diagnosed. The contact was informed that the weld on the catalytic converter was cracked. The contact was informed that the catalytic converter needed to be repaired or replaced. The vehicle was not yet repaired. The manufacturer and local dealer were notified of the failure, but no assistance was offered. The failure mileage was 38,000.

The contact owns a 2020 Ford Explorer. The contact stated that while driving at an undisclosed speed, there was an abnormally loud sound coming from underneath the vehicle. Additionally, an abnormal exhaust odor was detected while the vehicle was idling. The vehicle was taken to an independent mechanic who diagnosed that the failure was related to customer satisfaction program: 21b35 (right-hand catalytic converter and right-hand and left-hand exhaust flexible pipes) however, the VIN was not included. The vehicle was not repaired. The manufacturer was made aware of the failure and advised the contact to file a complaint with the NHTSA hotline. The failure mileage was approximately 47,500.

The contact owns a 2017 Ford Explorer. The contact stated that while driving at various speeds, the vehicle was jerking, vibrating, and transmission was slipping. The vehicle was taken to an independent mechanic who diagnosed that the torque arm, engine mount, axle shaft, and catalytic converter were all damaged due to the jerking and vibrations from the vehicle. The vehicle was repaired. The vehicle was later taken to the local dealer who performed service repairs under an unknown customer satisfaction campaign however, the failure persisted. The manufacturer was notified of the failure, but no assistance was offered. The failure mileage was 46,000.

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The contact owns a 2013 Ford Explorer. The contact stated that after starting the vehicle, the check engine warning light illuminated. The vehicle was taken to a local dealer where it was diagnosed but the failure was not determined. The check engine warning light was reset and the contact was informed that the check engine warning light was due to the air filter that needed to be replaced. The vehicle was repaired however the failure recurred. The contact stated that she purchased a scanner to check on the codes herself and that a code relating to the catalytic converter was displayed. The vehicle was then taken to an independent mechanic where it was confirmed that the catalytic converter failed. The vehicle was not repaired. The manufacturer was not notified of the failure. The approximate failure mileage was 14,000.

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When using the defrost or air conditioner or just having the fan on, exhaust fumes enter the cars cabin. Its very troublesome that when I took it to a Ford dealer and they checked it out and said the catalytic converter was cracked but told us Ford had no fix for it. Its very dangerous especially in the morning time when you need to use the defrost you have roll all the windows down and freeze you butt off.

Tl the contact owns a 2018 Ford Explorer. While driving at an unknown speed, there was a sulfur odor coming through the air vents in the vehicle. The failure caused the contact to become nauseous and dizzy. The contact was concerned for her safety. Winner Ford (250 haddonfield-berlin rd, cherry hill, NJ, (856) 428-4000) diagnosed that the sulfur odor was coming from the exhaust and the catalytic converter. The dealer informed the contact that the vehicle was operating normally. The vehicle was not repaired. The manufacturer was notified of the failure and opened a case. The failure mileage was 3,500.

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The contact owns a 2003 Ford Explorer. While driving 60 mph, on February 17, 2008, the engine shut off immediately without warning. Several vehicles were rapidly approaching the contact, which nearly caused a fatal crash. There were no warning lights present prior to the failure; however, after the engine shut off, all of the lights illuminated on the instrument panel. The vehicle was towed to an independent mechanic and diagnosed. The mechanic was unable to restart the vehicle. The dealer diagnosed the vehicle and stated that the catalytic converter needed to be replaced. The part was ordered and may be available by next week. The vehicle has been at the dealer for two weeks. The manufacturer's president was notified on two occasions and the secretary forwarded the messages to a liaison. The contact wanted the vehicle replaced, but the liaison stated that she could not assist. The contact saw on the news that there was a manufacturer's recall and filed case number 0490000518. The manufacturer stated that there were no existing recalls related to the failure. The following failures occurred with the previous owner: on March 1, 2004, the ring and pinions failed, on March 31, 2004, the pinion valve leaked, was damaged, tested and repaired. On April 14, 2004, while driving approximately 55 mph, the front pinion seal was leaking and replaced. The upper bearing was also repaired. The VIN appears to be invalid. The failure and current mileages were 40,000.

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The contact owns a 2003 Ford Explorer. The contact stated that the vehicle failed to start and was towed to the dealer. The dealer stated that the catalytic converter was bad and needed to be replaced. The part was supposed to be available on may 10, 2007, but it still has not arrived. The repair is covered under warranty. The engine size was unknown. The current and failure mileages were 56,000.

Vehicle stalls after driving 20 miles or above on freeway. When on exit ramp,engine light turns on and the engine shuts off. I have to put it in park and start engine again. The vehicle also accelerates when stopped at light, while foot is on brake. The engine stalls to change into faster speed.

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Rear windshield wiper motor failed. Caused loss of visibility through back window. Rear power window motor failed. Accelerator pedal vibrates on acceleration. (usually while merging on to highways) parking brake indicator light does not always light when parking brake is active. Rattle and vibration from catalytic converter cover.

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Two problems. There is a strong rotten egg smell in my Explorer. I had the vehicle checked while under warranty, but was told there was no problem. Since the warranty expired the smell has become stronger. I had it checked, and the Ford service department said it would cost $600 to repair. The other is a shimmy at 40 miles per hour. The service department just rotated and balanced my tires. I had this done a month earlier and it did not solve the problem. The vehicle still shimmies badly at 40 mph.

There is a sulfur smell emitting from the exhaust. This is apparent while driving with the windows open or closed with the heat/ac on. After waiting six weeks for the backordered converter to arrive, it was installed and the pcm was reprogrammed with the latest calibration update. It is my understanding that there are no additional repairs that would apply to my concern. I, along with my family, have been tolerating this odor concern since taking delivery of the vehicle. We are worried about possible toxic fumes that are being inhaled in the passenger compartment. I am very uncomfortable transporting my family in this vehicle.

Consumer is concerned about toxic gasses inside of vehicle. There is a odor coming inside of vent area.

The catalytic converter is not functioning properly and is producing a strong "rotten egg" smell. I am worried about the toxicity and general safety of the fumes being produced, not to mention the nauseating effect the fumes have. The local dealership says that the Ford field service engineer does not have a fix and that this is a major problem with the Ford Explorer. The local dealer also states that they are beginning to receive complaints from crown victoria owners. I plan to return the vehicle to the manufacturer using mississippi's "lemon law. ".

There is a sulphur smell coming into car while driving. Fumes are overwhelming, causing dizziness/ naseua, etc. On this particular car, the dealer tried 3 times to repair. None of the fixes worked. Car still has sulphur smell.

There's a smell in vehicle. Consumer smells exhaust fumesthat smell like rotten eggs. Took to dealer, and they can't remedy problem.

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Catalitic converter malfunctioned.

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While driving 60mph vehicle vibrates. Vehicle pulls to the right severly. Steering wheel is crooked, pulls to the left. Dealer contacted. Also, consumer states that there is very bad smell from catalytic converter which Ford says it is normal.

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From the date of purchase there has been a smell, both inside and outside the vehicle. A burning smell, at times the smell of rotten eggs. This smell causes me to be nauseaous. The dealer checked this on the computer, stated everyhing is okay. The computer results verify that the exhaust system is functioning within Ford standards.