About this problem
Exhaust fumes in the cabin happen when exhaust gas finds its way inside, usually through gaps in the rear of the body or through a cracked exhaust manifold. Owners describe a smell of exhaust, headaches or nausea, especially when accelerating hard or using the air conditioning. Exhaust gas contains carbon monoxide, which has no smell of its own, so the issue is taken seriously.
Across all owner complaints filed about the Ford Explorer since 2012, 1,165 (8.4%) describe exhaust fumes in the cabin, making it the most reported problem we track on the Explorer. The reports cluster on the 2014, 2015 and 2016 model years, and the 2015 drew the most, with 281. It tends to show up in the middle years of ownership: half of the owners who gave a mileage were between 13,000 and 52,000 miles. 15 reports describe a crash or fire linked to it. No recall covers it, but Ford has sent dealers service bulletins about it, listed below.
What owners report
Owners of the 2011 to 2017 Explorer report smelling exhaust in the cabin, especially when accelerating hard or using the air conditioning. Some police departments using Explorer-based vehicles reported similar problems. The 2014 to 2016 model years drew the most complaints.
How it gets fixed
Ford issued service bulletins that seal the rear of the vehicle and update the air conditioning settings, and a service program for some trucks. Owners who still smell exhaust should ask a dealer to check for open campaigns.
Typical cost: Bulletin repairs are often covered. A shop inspection for exhaust leaks costs about $100 to $200.
Complaints by model year
In owners' words
"Soon after buying my 14 Ford Explorer I noticed a strong exhaust smell in the cabin."
2014 Ford Explorer, 6,100 miles
"Smell of exhaust fumes and/or sulfur-type odors coming through air conditioning system under heavy acceleration, passing on highway, or when engine is under a load."
2015 Ford Explorer, 400 miles
"Purchased a used 2016 Ford Explorer w/24k on 8/23/16. Cab fills with carbon monoxide. Called dealership, we were 260 miles away, they said it was an easy fix, was told to turn off recycle for our trip back. Took vehicle back to dealership."
2016 Ford Explorer, 24,000 miles
Excerpts from public owner complaints filed with the National Highway Traffic Safety Administration, lightly trimmed.
Service bulletins and warranty extensions
Ford has sent dealers 15 bulletins that mention this problem on the Explorer. A bulletin tells technicians how to fix a known fault. It is not a recall, so the repair is usually free only while the car is under warranty or covered by an extension.
Customer Satisfaction Program 19N05: Certain 2011-2017 Model Year Explorer Vehicles - Carbon Monoxide Concern
Certain 2011-2017 Model Year Explorer Vehicles - Carbon Monoxide Concerns
Certain 2011-2017 Model Year Explorer Retail Vehicles - Carbon Monoxide Complaints
Exhaust odor in vehicle
Ford: when auxiliary climate control system is on, an exhaust odor, like sulfur, can be smelled.
Ford: there is an exhaust odor in vehicles when auxiliary climate control system is on and it smells like sulfur.
Government investigations
Engineering analysis EA17002 · 2012–2017 · opened Jul 2017, closed Jan 2023
Preliminary evaluation PE16008 · 2012–2015 · opened Jul 2016, closed Sep 2017
Before you buy a Explorer
- Drive with the air conditioning on recirculate and accelerate hard a few times; sniff for exhaust.
- Ask for proof the exhaust bulletin work was done.
- Check the rear hatch and tail-light seals.
Questions
Which Ford Explorer years have exhaust fumes in the cabin?
Complaints are highest for the 2014, 2015, 2016 model years. The 2015 drew the most, with 281 reports.
At what mileage does it usually start?
Among owners who gave a mileage, the middle figure was about 30,000 miles, and half reported it between 13,000 and 52,000 miles.
How much does it cost to fix?
Bulletin repairs are often covered. A shop inspection for exhaust leaks costs about $100 to $200.