Two problems related to engine exhaust system have been reported for the 2009 Ford Flex. The most recently reported issues are listed below. Please also check out the statistics and reliability analysis of the 2009 Ford Flex based on all problems reported for the 2009 Flex.
2009 Ford Flex cabin area fills up with carbon monoxide and catalytic converter smell on acceleration such as passing gear, getting into traffic from an on ramp, etc. Ford's repair was replacing baffles at the end of the exhaust system that they suspected were remaining closed on significant acceleration. Dealership performed repair but it made no difference. If windows are not rolled down to allow the exhaust gases to exhibiit the cabin area slight headache and burning of the eyes ensues. This problem seems to occur on about 1 out of 4 Ford Flexs and a solution has not been engineered. This is an important safety/health issue that needs to be addressed.
Smell car exhaust fumes inside the car when under acceleration and the heater is going. . Took it to Ford dealership to service writer. He did not accept the car for service or write it up because he could not smell it himself. The problem comes and goes. Smelled it as recently as today.