Ford Flex owners have reported 3 problems related to manifold/header/muffler/tail pipe (under the engine and engine cooling category). The most recently reported issues are listed below. Also please check out the statistics and reliability analysis of Ford Flex based on all problems reported for the Flex.
"takata recall" my engine light went on 2000 miles before my manufactures warranty expired. I have a Ford shop here, but they are rated so low and I hear nothing but bad stuff about them, so I called the next closest 95 miles away in spearfish, sd. I explained to the guy what code the engine threw, but my light is now off. He said not to come in, until my engine light came back on. Meanwhile my engine still hisses and the exhaust odor is so strong inside and outside of the vehicle. I have 36,879 miles on my 2016 and either have an exhaust leak from the headers or the manifold. The engine light won't come back on and noone will check the vehicle without it on. There is no reason for my "newer" vehicle to have an exhaust leak to this extent.
See
all problems of the 2016 Ford Flex
🔎.
Defective exhaust manifold. The exhaust manifolds are made with two types of metals stainless steel outside and cast iron inside. Well my turbo went out on my car and the vehicle was takin to villa Ford in orange California and they replaced the turbos. Two days later I loose boost again and the turbos exploded chunks of mettle like the first they said they checked to make sure no metal made it to intake and did compression test and all was good. Well I loose boost again and it was metal in turbo and ruptured boot at turbo it turns out the exhaust manifold was breaking off chunks into my intake system. I take it to them again and they replace the exhaust manifold and I tell them to smog it because tags are due. They had my car over 120 days and said they can't smog it yet because codes are missing to drive it and put some miles on it and I do so just to find that it won't pass smog so now Ford will not take responsibility for any of the damages more reimbursement for the thousands we paid to correct the matter. In closed are pics of the exhaust manifold and the chunks are blocking #1  cylinder from exhaust to exit so now I have compression loss in cylinder 1&3 and they tell me I need a new motor.
See
all problems of the 2011 Ford Flex
🔎.
Driving the vehicle on the highway and heard a clunk and felt a slight loss of power and control. Pulled over to check vehicle and noticed flames coming underneath the engine compartment. Car soon became engulfed and was a total loss. The origin and cause expert hired by our insurance company suspects an injector line came loose on the engine and sprayed fuel onto exhaust manifold.
See
all problems of the 2015 Ford Flex
🔎.