Two problems related to engine exhaust system have been reported for the 2011 Ford Flex. The most recently reported issues are listed below. Please also check out the statistics and reliability analysis of the 2011 Ford Flex based on all problems reported for the 2011 Flex.
There is a strong sulfur smell in the cabin after a hard acceleration, it smells similar to catalytic converter exhaust odor. Service department was able to replicate the odor but told me that they do not know how to fix the problem.
The exhaust muffler holding hook is severly rusted. Part was replaced by the dealer in 05/03/11. Replaced part is severly rusted again. Vehicle has 7500 miles only. The vehicle is driven to a minimum during the winter months. This is a potential hazard since the mufler could fall off the car while driving due to execive rust of the supports.