Exhaust Recall?

[Dhood]

We just bought a used 2020 Explorer Platinum with the 3.0 ecoboost. I didn't notice the noise when we drove it at the dealer, but probably just wasn't paying attention. When we got home or the next day when starting it up, I could hear the exhaust leak very loud. Of course it got more quiet the longer it idled but could still hear it with the hood up, or when goosing the accelerator. I have an appointment Monday morning for a Ford dealer to look at it. I crawled under it tonight and I can see the crack in the weld as well as black exhaust suit around where the leak is. With over 60k on it now, will factory warranty still cover this, or will Ford still cover it under this recall or bulletin everyone is talking about? I have extended warranty, but I doubt they cover converters. If nothing else, I'll make the dealer I bought it from pay for it since the did a so called inspection. They didn't even change the oil in it before putting it on the lot.

 

[Cdubya]

With over 60k on it now, will factory warranty still cover this, or will Ford still cover it under this recall or bulletin everyone is talking about? I have extended warranty, but I doubt they cover converters. If nothing else, I'll make the dealer I bought it from pay for it since the did a so called inspection. They didn't even change the oil in it before putting it on the lot.

Federal catalytic converter and emissions warranty is 8 yrs, 80kmiles.

 

[way2far]

I think I'm having the same issue you are experiencing. Sad part is that I've had both cats rewelded due to cracks (one through recall, and the other on my own dime). This is how mine sounds:

 

[Toe ball]

We just bought a used 2020 Explorer Platinum with the 3.0 ecoboost. I didn't notice the noise when we drove it at the dealer, but probably just wasn't paying attention. When we got home or the next day when starting it up, I could hear the exhaust leak very loud. Of course it got more quiet the longer it idled but could still hear it with the hood up, or when goosing the accelerator. I have an appointment Monday morning for a Ford dealer to look at it. I crawled under it tonight and I can see the crack in the weld as well as black exhaust suit around where the leak is. With over 60k on it now, will factory warranty still cover this, or will Ford still cover it under this recall or bulletin everyone is talking about? I have extended warranty, but I doubt they cover converters. If nothing else, I'll make the dealer I bought it from pay for it since the did a so called inspection. They didn't even change the oil in it before putting it on the lot.

My 2021 passenger side catalytic converter broke ate the bottom seam. Exhaust pipe dropped to the road. Had to get towed. I reported it to the appropriate government authority (I forget the acronym). Maybe there’ll be a recall one day

 

[Natasha Bilodeau]

My 2021 passenger side catalytic converter broke ate the bottom seam. Exhaust pipe dropped to the road. Had to get towed. I reported it to the appropriate government authority (I forget the acronym). Maybe there’ll be a recall one day

My 2021 now on its 2nd catalytic converter change. Likely an underlying issue. Cracks both times. Currently waiting for a full check.

 

[Toe ball]

My 2021 now on its 2nd catalytic converter change. Likely an underlying issue. Cracks both times. Currently waiting for a full check.

Yeah, my passenger side cracked. I had a welding shop fix it. The dealer wanted me to wait a month and a half to even look at it. The welder put a sleeve in the exhaust pipe so that it wouldn’t break again. I had him do the same thing to the other side, $70. The quality of the suv leaves a lot to be desired.

 

[way2far]

Hi all, hope everyone is having a great holiday season!

As an update, after searching through multiple videos on the exhaust leak subject, I think I found the issue. I plan on checking this later today on mine.

For a quick review, this is the noise I'm having:

Here's a video showing that flex pipe is causing the "leak" or "rattle/buzz" noise:

Unfortunately it seems, per the mechanic in the video, that Ford isn't willing to make a fix outside of mounting a clamp on the flex pipe which doesn't cure anything.

Should I troubleshoot and find the same issue, I plan to drop it off at the dealer to confirm Ford's stance.

 

[jwuonog]

Has anyone had any luck with getting the cracked DP replaced by the dealer while also having an aftermarket catback on it?

I recently installed a Thermal 3" and discovered in the process that my driver downpipe was cracked. I am still under powertrain warranty, ESP, and emissions warranty, but the dealerships near me are not very mod-friendly.

 

[SoySauceSoakedSaltine]

Has anyone had any luck with getting the cracked DP replaced by the dealer while also having an aftermarket catback on it?

I recently installed a Thermal 3" and discovered in the process that my driver downpipe was cracked. I am still under powertrain warranty, ESP, and emissions warranty, but the dealerships near me are not very mod-friendly.

I'd roll the dice and put the OEM exhaust back on then go up there and see if they'd replace the DP. I figured you'd have better chances on them not noticing the exhaust was toyed with than going in there with the aftermarket and them flat out denying the warranty claim saying the DP could have been damaged while making the switch. BUUUUUUT if you don't have your OEM then bring a $50 and a case of beer with you when you talk to the SM.

 

[Cajun Heat]

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

That convertor should be covered under warranty if you fit the criteria.

https://www.epa.gov/transportation-...frequent-questions-related-transportation-air

The Design and Defect warranty covers repair of emission control or emission related parts which fail to function or function improperly because of a defect in materials or workmanship for 2 years or 24,000 miles (whichever first occurs), and the specified major emissions control components mentioned above for 8 years or 80,000 miles (whichever first occurs). The manufacturer can deny this warranty coverage if evidence shows that the emission component failure was caused by improper use or maintenance and not caused by a defect.