Manifold/header/muffler/tail Pipe Problems of Ford Explorer - part 1

The contact owns a 2020 Ford Explorer. The contact stated that upon raising the front passenger's side power window switch, the window rolled up and then rolled back down unintendedly. The vehicle was taken to the dealer, where the power window control module was reset. The contact stated after the dealer had performed a rearview camera recall repair on the vehicle, messages advising that the traction control and the other drive modes were inoperable were displayed. The dealer replaced the throttle body and an unknown part. Additionally, the contact stated after the dealer had lifted the vehicle for servicing, the dealer noticed that the catalytic converter, the mufflers, and the shock absorbers had failed. The dealer informed the contact that the shock absorbers were leaking fluid. The dealer determined that the catalytic converter, the mufflers, and the shock absorbers needed to be replaced. The dealer had ordered the parts. The vehicle was not repaired. The manufacturer was notified of the failure and a case was opened. The manufacturer referred the contact to the NHTSA hotline for assistance. The failure mileage was approximately 70,000.

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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.

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The contact owns a 2013 Ford Explorer. The contact stated while driving 30 mph, he started to smell exhaust fumes inside of the cabin of the vehicle. The contact stated no warning light was illuminated. The contact stated while inspecting the vehicle, he noticed the exhaust manifold was faulty and leaking. The vehicle was not diagnosed nor repaired. A dealer was not contacted. The manufacturer had been informed of the failure. The failure mileage was approximately 169,234.

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When backing up and the wheel is turned there's a hesitation then what feels like I hit something. (a clunk w/o the noise ) then when break peddle is pressed the car shimmies bad . I also smell antifreeze coming from the heater vents . Brought it back to dealership for them to fix it since it was just purchased there . . They had it for 5 days . . Nothing got fixed. They turned front rotors and topped off fluids. I do believe that I have a bad rear tow bearing or a u-joint. Breaks not sure but the car is worse than before. Still smell antifreeze and there's a dark film on the windshield which indicates a bad heater core. I've brought this to the attention of the dealership bit they won't return my calls or emails or texts. I believe I was sold a lemon. There's an oxidation on the engine and a black stain on bottom of engine. Also the exhaust manifolds have been replaced. This is a 2017 and shouldn't have this many issues .

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For the past several months had a slight ticking sound at warm or cold startup. Was getting tired/achy while driving more than an hour. The sound became much louder over the weekend. It has been diagnosed as a cracked front exhaust manifold and may have been leaking CO into the passenger compartment.

Cracked exhaust manifold. Car has 75k miles. $1300 repair bill for new manifold and attached sensors.

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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.

Tl the contact owns a 2012 Ford Explorer. The contact noticed an abnormal exhaust odor coming from the ventilation system without warning. The contact mentioned that the odor was only present when the vehicle was idling. The vehicle was taken to hastings Ford inc (3013 e 10th st, greenville, nc 27858, (252) 758-0114) where it was test driven and determined that the exhaust was leaking at the manifold. The vehicle was not repaired. The failure recurred multiple times. The manufacturer was made aware of the failure and provided case number: 25071531. The failure mileage was approximately 111,000.

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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.

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Front manifold crack that is allowing exhaust fumes to enter the vehicle.

When idling cabin fills up with what appears to be smoke from mufflers. Fell asleep in the car while idling, woke up dizzy and thru up shortly after, strong headache after. Rust around the lock on the trunk lid.

When accelerating we can smell exhaust in the cabin of our vehicle. This has been an ongoing issue for more than a year. We have to roll the windows down to get air. On trips from phoenix to san diego thru the mountain passes we have gotton dizzy from exhaust smell. I have taken it to the dealer 4+ times to complain about this issue, dealer has said its a known issue with no fix. You can smell the humidity of the exhaust as well as the burnt oil. Every time I get in my vehicle with friends, I'm embarrassed of smelling exhaust and hope it doesn't affect health of anyone. We can see the exhaust soot building up along the engine block and exhaust manifold but the dealer told us thats normal road grime.

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We have experienced a clicking noise on our car over the last couple of weeks and my wife has been complaining of headaches and fatigue during the same time as well. We took the car into the shop and it has been identified as a crack exhaust manifold which would cost us $1,100 to fix. I researched and saw this 1. 3million reports of the samething. I called Ford and they refused to help with the repairs as there is no recall on this issue. I am not sure how you don't recall a very known issue that I now see personally causes health issues that could be fatal - plus you get with a cost that they are aware of. Not good business and very dangerous - it is sad it may take a fatal accident before Ford recalls this.

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.

Tl the contact owns a 2014 Ford Explorer. The contact took the vehicle to rowe Ford auburn (699 center st, auburn, me 04210) for routine maintenance and was informed that the exhaust manifold was leaking and needed to be replaced. The manufacturer was notified of the failure. The vehicle was not repaired. The approximate failure mileage was 165,000. The VIN was unavailable.

Tl-the contact owns a 2013 Ford Explorer. The contact stated that while driving approximately 30 mph, noticed the odor of exhaust fumes inside the cabin. The contact rolled the window down heard a noise emerging from under the engine compartment. The vehicle was taken to the dealer quirk Ford, 540 southern artery, quincy, MA 02169, they determine that the exhaust manifold was fractured and needed replacement. The manufacturer was not notified of the failure. The vehicle was not repaired. The approximate failure mileage was 65,239. Bp.

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.

Tl the contact owns a 2017 Ford Explorer. While driving various speeds, the contact and passenger experienced dizziness, headaches, and felt as if they would lose consciousness. Medical attention was not received. The vehicle was taken to ciocca Ford of quakertown (321 s west end blvd, quakertown, PA 18951, (215) 536-8600) where it was diagnosed that there was a carbon monoxide leak. The ventilation system and muffler were replaced, but the failure persisted. The manufacturer was not made aware of the failure. The failure mileage was approximately 18,000.

Odor noticed in vehicle cabin intermittently while driving, particularly while accelerating. Have now found out that the vehicle has a cracked exhaust manifold.

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.

This is a follow up to NHTSA id 11019920 filed 8/26/17. Exhaust odor, smells like sulfur, strong, pungent, coming through dahs board vents during sustained acceleration and shortly after. The problem is repeatable every time: put vent system in recirculation mode, sustained acceleration over 3,000 rpm, wait 5 seconds, strong sulfur odor comes through dash board vents. I am now experiencing headaches on a consistent basis as I have been driving the vehicle more often for commuting since purchasing it in March 2017 with 25k miles. I am seeing a doctor and am building a case for more severe headaches with increased driving in my Explorer. Today, I decided to look under the vehicle - I am including photos of the exhaust manifold which shows a crack near the pipe-to-flange connection. And, no, my vehicle is not a police cruiser and it does not have aftermarket parts installed. How many more complaints do you need? TSB 14-0130 is Ford's cheap attempt to hide a very serious problem and avoid a costly recall of over 1 million vehicles. The evidence continues to mount, injuries have occurred, countless Explorer owners have expended much resources in filing complaints, and Ford says, "these vehicles are safe. We have not found a safety issue here". Ford has issued tsbs which do not address the problem. Their latest insult to offer to "inspect and repair" rear lift gates and drain valves, and reprogram the air circulation system is laughable, nothing more than a distraction to hide the real problem. Ford should put every Explorer on a lift and inspect the exhaust manifolds, and do extensive testing of the vacuum system that is connected to the air circulation system. Nhtsa: why is it taking you so long to address this problem? does someone need to die before you or Ford take this matter seriously? you have the evidence you need to force a recall, now!.

I have a 2014 Ford Explorer with 89k miles. I recently brought it to the dealer for an the smell of exhaust fumes inside the vehicle. The smell comes at higher speeds (above 50 mph) and when the vehicle comes to a full stop. The vehicle must be at full operating temperature before you can smell the exhaust fumes. Currently the solution I received from the dealer is to replace the muffler and the dual air extractor.

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.

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.

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.

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.

This make/model/year has a known factory defect that caused the exhaust manifold to blow exhaust directly into the cabin. I had to force the dealer to fix this, as they argued exhaust is not dangerous. I have attached the instructions on how to fix this, from the factory, proving it was a known serious issue, not disclosed to me. The dealership did a horrible job in the "repair" - having broken other parts of the car in the process. After they "repaired" the car, it began randomly shuddering, while idling. I have attached a video of it. You will need to turn up the volume to the max, as youtube compressed the sound terribly. I have one witness to this happening twice. The engine starts vibrating with such ferocity that it sounds as though the vehicle is about to explode. The witness is willing to testify in court. . Read more...

The contact owns a 2017 Ford Explorer. The contacted observed a hole in the "y" portion of the exhaust tail pipe without warning. The contact took the vehicle to the dealer (bob davidson Ford Lincoln, 1845 joppa rd, baltimore, MD, 21234) where they observed the hole and welded it closed. The contact was informed that the vehicle was repaired, but no invoice or paperwork was provided. The manufacturer was neither contacted nor made aware of the failure. The failure mileage was approximately 8,000.

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.

I have a 2017 Ford Explorer platinum which I purchased brand new on November 25, 2016. It took me a while to realize but every time I would drive the Explorer, my eyes would get very heavy and I would develop a headache. I commute 42 miles each way for work and I cant count how many times I almost fell completely asleep. After some research, I found out that this was a common problem to due to possible carbon monoxide (CO) leaks entering the vehicle through the ventilation system. I immediately contacted my local Ford dealership and had this looked at early this year. Ford replaced the exhaust manifold and I noticed a major difference in how I felt when driving the vehicle. Recently, in the past two weeks I have been experiencing the same issue again with headaches and feeling sleepy while driving. I have made several attempts to contact Ford corporate about this and I have not received any response. I would like for them to either completely fix the issue or allow me to trade in my vehicle for another one. This is truly a hazard not only to myself but for my passengers (wife and kids) and to others on the road. Please help to get this resolved. . .

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.

The contact owns a 2014 Ford Explorer. While driving 35 mph, an exhaust odor emitted into the vehicle through the front and rear air vents during acceleration. The vehicle was taken to the dealer where the muffler was replaced. The vehicle was repaired; however, the failure recurred. In addition, the instrument panel failed to illuminate while driving 20 mph. The contact coasted the vehicle to the side of the road and the gear shifter seized. The contact restarted the vehicle and drove home. Once the contact arrived at home, the vehicle lost power, the alarm and horn sounded, and the tailgate opened. The vehicle was taken to the dealer where the gear shifter was replaced. The manufacturer was notified of the failures. The approximate failure mileage was 24,191.

In summer 2015 we began smelling exhaust in the vehicle when the air conditioner was on. It started out as a mild smell and continued to get worse over time. We mentioned it to our service advisor multiple times who could not duplicate the issue. After many attempts, we got the dealership to duplicate the issue and admit there was an issue but unfortunately they could not fix it. As time went on, the smell was present all the time whether or not the air conditioner was on. In early 2018, we brought the vehicle to the dealership to perform the Ford authorized fix for this known issue (sealing holes, reprogram the a/c, etc. ). However, the smell never went away and we brought the vehicle back twice to have it verified. This last time the dealership stated that the exhaust manifold was cracked and that there was nothing that Ford would do and that we had to pay for a replacement. The vehicle has 95k miles on it currently.