Exhaust Recall?

minuteman3 · Aug 20, 2021

Saw this on CarFax after receiving an email "warning". I checked the NTSB site and there's no mention, and when I plugged my VIN into the recall checker on the Ford Owner site it came up indicated "None." Anyone familiar with this?

Screen Shot 2021-08-20 at 4.45.18 PM.png

I'm curious because I've been noticing a very faint "chugging" sound on acceleration at times and I was wondering if this might cause something like that.

Cheers

Ken

Big Turk · Aug 20, 2021

Hi,

I just received a recall notice for my 2020 ST (made in September 2020) for a possible crack in the left-hand catalytic converter. An emissions issue. No real safety concern.

Hope this helps,

Ron

Cdubya · Aug 20, 2021

Got the same Carfax message. I'm going to wait until I get notified of a recall via Ford Pass. Their past recalls never affected my build date and I never got a recall notice on Ford Pass.

hbalek · Aug 20, 2021

Cdubya said:

Same here to all of the above!

Mobius87 · Aug 20, 2021

I received a paper copy of this recall from Ford.

Sent from my SM-G991W using Tapatalk

Big Dummy · Nov 8, 2021

I guess this would be the correct thread to post on this. My 2020 had been rattling on startup and while driving for awhile, I looked at the flex couplings and the passenger side had broken, I think it was partly due to the hose clamp put on to stop the rattling. I took it to an exhaust shop, they put a woven flex coupling on and informed me my Drivers side Cat was starting to crack. I looked at it when I got home and sure enough it is cracked at the top side flange weld. Scheduled replacement with the dealership, no big deal…. This was 2 weeks ago…. This past Saturday I changed the oil and noticed the drivers side Cat mounting bracket weld has broken off and rattles like crazy, I looked all over the passenger side and looks solid. I dropped it off today to have the cat and the intermediate pipes replaced, received a call from dealer that drivers side is all done but have to replace the passenger side Cat due to a crack and will be completed tomorrow. Thank god for warranty! Pics are attached if anyone needs a visual reference on where cracks could be occurring. The pics are only of the drivers side cat, top flange weld crack and the lower mounting bracket.

hbalek · Nov 8, 2021

Big Dummy said:

I guess this would be the correct thread to post on this. My 2020 had been rattling on startup and while driving for awhile, I looked at the flex couplings and the passenger side had broken, I think it was partly due to the hose clamp put on to stop the rattling. I took it to an exhaust shop, they put a woven flex coupling on and informed me my Drivers side Cat was starting to crack. I looked at it when I got home and sure enough it is cracked at the top side flange weld. Scheduled replacement with the dealership, no big deal…. This was 2 weeks ago…. This past Saturday I changed the oil and noticed the drivers side Cat mounting bracket weld has broken off and rattles like crazy, I looked all over the passenger side and looks solid. I dropped it off today to have the cat and the intermediate pipes replaced, received a call from dealer that drivers side is all done but have to replace the passenger side Cat due to a crack and will be completed tomorrow. Thank god for warranty! Pics are attached if anyone needs a visual reference on where cracks could be occurring. The pics are only of the drivers side cat, top flange weld crack and the lower mounting bracket. View attachment 8414 View attachment 8415 View attachment 8416

I suspect I have the same problem with mine. Which would explain not only the rattling noise but also the exhaust fume smell.

Bryantbjb · Nov 11, 2021

Big Turk said:

Got the same report from the dealer today while they were performing the recall for the rear view camera. Dealer reports that parts are not available.

UpinBst · Nov 16, 2021

Nov 15 2021 3498 - Announcing - Emission Recall 21E11 - Full Bulletin

NEW VEHICLE / DELIVERY HOLD - Emission Recall 21E11 - Certain 2020-2021 Explorer ST and Police Interceptor Vehicles Equipped with a 3.0L EcoBoost Engine - Left-Hand Catalytic Converter Replacement and Powertrain Control Module Reprogram. Refer to FMCdealer.com for additional information.

MRosier · Nov 16, 2021

Bryantbjb said:

I work as a technician at Ford, I recently replaced a left cat. converter on a 2020 with 58k miles because of this cracked weld at the inlet flange. The leak was very audible even just at idle. The “recall” parts are assumed to not be available until after the owners letters are mailed out which is February 2022 last I heard. Anyway, the faulty parts can still be replaced under warranty. I will say the welds looked much more robust on the replacement pipe. Not sure if it was the actual updated part or not. Even though this is labeled as an emissions related recall, it actually is very safety oriented because the risk of exhaust fumes entering the cabin!

Blue Beast · Nov 16, 2021

Good Info Thanks

1big6fan · Dec 10, 2021

Just got back from NC with the exhaust pipe behind the right side muffler hanging down about 2 inches. Totally broken off. On a vehicle that's 2 years old. Covered under warranty of course and I had to take it in for the backup camera anyway. Both issues did not qualify for a loaner. Had to order exhaust pipe and muffler. Parts 2 week out. Still no loaner. Also need to replace both catalytic converters. They have no idea when those parts will be in. Pretty much a shit show.

CapTom · Dec 11, 2021

They just replaced the converter on mine/ It was about a week wait for the part.

hbalek · Oct 14, 2022

CapTom said:

Finally had them check and they ordered my left catalytic converter replacement. Crossing my fingers on this one!

Geo Tracker · Jun 11, 2024

Had my LH catalytic converter replacement by warranty recall a year ago and looks like it needs another one according to the dealer. Making loud exhaust sounds on cold start, then settles down as it heats up. Noticeable again at high RPM. I thought is was only a leak at the gasket and clamp under the driver's feet area. This is what I was seeing. Dealer still evaluating the issue, leak vs full replacement again. Is this black spot normal, don't have it on the RH side. Dealer advised the CC was under warranty for 5yrs 80K , so I told them to proceed with necessary repairs. They are keeping it overnight. I think they will replace it all from the CC on down to the black connection. I think the CC may be an expensive item?

EDWYER · Jun 12, 2024

Yeah the OEM CC isn't cheap by any means.

LuvmyST · Jun 12, 2024

Exactly which ST are we talking about here? Or are the emissions the same for both the 2020 ECO and other for the ST? I’ve never seen anything for my 2020 via any means, that is notifications. Clearly I’m concerned now

way2far · Jul 12, 2024

Just had this recall done on the left CC. Of course the right one was cracked, so needed that one replaced as well. Mileage is just under 30k for reference.

Geo Tracker · Jul 12, 2024

Geo Tracker said:

UPDATE: Dealer also replaced the one shown in the photo above as a bad CAT. The next week I was back with a Bank 2, Sensor 1 (o2) message on my app and check engine light. Dealer advised P2240 and P2629 and replaced the sensor, cleared the check engine light, but the light and errors returned during testing. Next day, they replaced the same sensor again and it appears to be ok now. 1st CAT recall, 2nd CAT Emissions Warranty, the sensor covered with extended warranty. Rental car was offered but I didn't need one at the time.

Toe ball · Jul 17, 2024

The passenger side exhaust pipe on 2021 ST broke off the catalytic converter this past Sunday afternoon. The weld broke at the bottom of the catalytic converter. I checked my VIN and i'm not included in the recall. I called the dealer and they confirmed it. They told me to tow it in and they'll look at it. No way. The pipe broke off the back of the muffler and they wanted $3200 to fix it. Eff that. Local shop charged $200 to fix it.
I've had Fords for 40 years and no troubles like this. Cheap materials

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