Exhaust smell

[Dale5403]

Question. Did y'all smell the exhaust all the time and that is what made you suspect broken cats?

Reason why I ask is that I smell exhaust only under hard launch/acceleration. Never under normal conditions.

With mine I had very little smell inside. And only on start up. You could hear it when cold also.

 

[Cdubya]

This the driver's side. I was under the car looking at something else when i noticed the crack at the weld. No smell, no noise. Some have it up by the flange but the same weld material is likely suspect throughout. Oddly, the recall specifically mentions the left side. Why wouldn't the right side be affected too? I'm asking because a recall will be performed under any mileage but if you are out of warranty, the right side won't be covered.

 

[bmidd]

Our drivers side cat was cracked halfway around at the weld, replaced under warranty. While there, they replaced the oil pan, it had a leak at the left front of the pan. Did the PCM update and the parking brake auto on thing, no big deal, just touchthe gas and it releases.

 

[hbalek]

Our drivers side cat was cracked halfway around at the weld, replaced under warranty. While there, they replaced the oil pan, it had a leak at the left front of the pan. Did the PCM update and the parking brake auto on thing, no big deal, just touchthe gas and it releases.

Mine got worse and worse since the first year and at 3 years had my catalytic converter replaced on the driver's side. Now I'm happy to report no more exhaust smell even on cold days.

 

[Autoworker]

Just received the recall in the mail yesterday.

 

[hbalek]

Just received the recall in the mail yesterday.

I never received a recall letter but had it inspected and replaced under warranty.

 

[Dale5403]

I never received a recall letter but had it inspected and replaced under warranty.

Same for me. I think the parts just became available so that's why recall letters are going out. At least that is what my service advisor said.

 

[DaveG ST]

My catalytic converter was replaced some time ago, maybe last Spring. Anyways, the first dealer order the parts but they never came in. Another dealer ordered the parts and sent in pictures to Ford, saying Ford required this in order for them to receive the parts. They had the converter within in about a week. My ST no longer has the exhaust smell, but she sure is noisy when you first start it. The exhaust quiets down after warm-up. I am at 42K miles. Any thoughts on this, possibly 'normal'?

 

[GoPackGO]

https://static.nhtsa.gov/odi/tsbs/2021/MC-10204044-0001.pdf

Recall 21E11

Thx. I brought the 2020 Explorer ST in due to exhaust smell in cabin(I mentioned it at my last oil change about a month ago and they said they couldn't find anything). I noticed it getting worse so I brought it in with a print out of the recall link sent to me - big thx. Notes from dealer said factory recall 21E11. installed catalytic converter driver side cracked at flange. Reprogrammed PCM per recall. Again thanks to the forum as I suspect having the recall with me was a plus. I will say when I look for recalls using my VIN nothing popped up so ??? Oh well all is good. Happy Holidays to all.

 

[Harley Helo Guy]

Just received the recall letter (Emission Recall 21E11) for my 2020 Explorer ST yesterday. I smell gas fumes in the car at various times and hear a tinny vibration sound when accelerating. I brought up the gas smell to the dealership in the past but of course they couldn't replicate it during the short drive around the block. I've got an appointment with the dealership for the recall next week. The service rep says it will be an "inspection" to determine if there's any need to "replace the left-hand catalytic converter". In my view, the replacement of the catalytic converter needs to happen regardless of what their inspection results are. I view it as a mandatory retrofit of a defective part and will make that opinion known to the service writer (in a casual way) when I bring the vehicle in.

Also, the information provided by the posters above is greatly appreciated. I'll give an update after my appointment next week.

UPDATE on 12/27/2022: brought the ST into the Dealership for the recall inspection, which took less than 30 minutes. They determined the part needs to be replaced and placed it on order (without prompting from me). The inspection took less than 30 minutes. Once the part arrives, installation will take a solid half day. Part expected to come in early next week, so roughly 7 calendar days.
FINAL UPDATE: the catalytic converter was replaced on 2/24/2023 with 39K miles on the odometer, the dealer also did safety recall notice 23S02/NHTSA recall 23V022 (a software download for rearview camera). All parts for the catalytic converter arrived within two weeks of the initial order, with the exception of the catalytic converter itself, which took close to two months to arrive. Both recalls were completed together in a single half-day. Very satisfied with the dealership, my Explorer ST and Ford in general.

 

[mcfarlrm]

I really don't understand how these dealerships are so incompetent to not be able to "replicate" this known issue. I honestly believe that some folks on this forum have more knowledge than a lot of Ford service advisors and techs. When I took mine in for the first time with this issue and the recall notice, they mentioned that the noise I was hearing was my wastegate rattling and that it was normal!!! I couldn't believe my ears. After I refused to take that as an answer, they "reinspected" and mentioned that it was a cracked cat that was making the noise and causing the fume smell within the cabin.

 

[Harley Helo Guy]

I really don't understand how these dealerships are so incompetent to not be able to "replicate" this known issue. I honestly believe that some folks on this forum have more knowledge than a lot of Ford service advisors and techs. When I took mine in for the first time with this issue and the recall notice, they mentioned that the noise I was hearing was my wastegate rattling and that it was normal!!! I couldn't believe my ears. After I refused to take that as an answer, they "reinspected" and mentioned that it was a cracked cat that was making the noise and causing the fume smell within the cabin.

It's almost like they don't want to mess with it unless the customer isn't footing the bill for the repair.

 

[Stoffius]

Just got the Emission Recall 21E11 letter. Drivers side exhaust shakes like crazy and sounds awful. Adding to the repair list when dropping off on Monday.

 

[Sooner94]

No recall listed for the catalytic converters on my 2021 Explorer ST but TWO are cracked and scheduled to be replaced under warranty. My ride is ~45,000 miles on it. The cats will be replaced at the same time service is scheduled for recall replacement for a rear-end bolt and reprogramming of the back-up camera - getting the infamous blue screen instead of a functioning back-up camera. The hands-free calling with bluetooth is totally unacceptable as well - not related to signal received by the cell phone. Very disappointed to have these issues.

I have had CONSTANT issues with the back-up camera in my 2015 Ford Expedition XLT - purchased new as well. That was replaced 4X and even after the last immediately replacement the camera, again, immediately had issues. Figured Ford would have resolved the back-up camera issues by 2021 when I purchased my new Explorer ST.

Ford - do better. :-/

 

[KegsBdry]

Had an oil change and the catalytic converter recall done. They found a cracked midpipe flex section. I'm not even at 50K miles yet and they want me to pay for it! This doesn't make sense. I only use the 93 octane gasoline. And I have a premium extended warranty. But they only cover exhaust up to 36K miles.

What could have broken it other than poor quality or when they did the catalytic converter work? Does this mean I have to get a new exhaust every 50K miles? That's BS

 

[Cdubya]

I thought there was a TSB for failed midpipe. Mine failed a while ago. Makes sense when it is rattling away that it will ultimately wear out. I decided to replace it with the Lethal midpipe than to deal with another OE midpipe. Much higher quality flex section and no rattle. Ultimately, unless you are still under bumper-to-bumper warranty, a lot isn't covered. One reason I didn't get the extended warranty either.

 

[KegsBdry]

Follow up:. Received a call from the local shop's service manager. He stated that I could contact Ford Corp directly and open a claim if I found it was unfair to pay for an exhaust that broke only a few thousand miles after it's warranty ended.

2 weeks later, Ford corporate calls me to say the $700+ job will not only be taking care of under warranty but they also provided 3 years/45K miles (starting at my current odometer, 49K) FREE OIL changes for being a loyal Ford customer!!!

Honestly, I thought I would have to eat that bill. But I think that was pretty amazing of Ford.

 

[Harley Helo Guy]

Follow up:. Received a call from the local shop's service manager. He stated that I could contact Ford Corp directly and open a claim if I found it was unfair to pay for an exhaust that broke only a few thousand miles after it's warranty ended. 2 weeks later, Ford corporate calls me to say the $700+ job will not only be taking care of under warranty but they also provided 3 years/45K miles (starting at my current odometer, 49K) FREE OIL changes for being a loyal Ford customer!!! Honestly, I thought I would have to eat that bill. But I think that was pretty amazing of Ford.

Glad Ford Corp came through for you. Maybe your extended warranty influenced their decision after all.

 

[dadsfaSTtaxi]

Has anyone gotten a p219b code (engine control system has detected a large variance between the engine cylinders on the bank 2 side of the engine) after the catalytic converter recall being done? My dealership cannot get the CEL to stop coming on after the recall. It's driving me crazy thinking my 60,000 car is a brick. It needs to pass emissions and looks like I'm screwed. Any advice?

 

[Harley Helo Guy]

Has anyone gotten a p219b code (engine control system has detected a large variance between the engine cylinders on the bank 2 side of the engine) after the catalytic converter recall being done? My dealership cannot get the CEL to stop coming on after the recall. It's driving me crazy thinking my 60,000 car is a brick. It needs to pass emissions and looks like I'm screwed. Any advice?

Are you getting any other trouble codes along with it? This link might be helpful:

https://www.700r4transmissionhq.com/p219b-ford-f150/