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Confirmed: Some Exhaust in Cabin when Acceleration issue is From the Front

Discussion in 'Stock 2011 - 2019 Ford Explorer Discussion' started by Black Eyed, December 8, 2017.

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    1. Black Eyed

      Black Eyed Member

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      Hello.

      Yes, It's true and confirmed at least on two Explorers has this issue including mine.

      After My dealer did TSB in 2016, i didn't notice the smell then it's back again. i tried to seal everything in the back of my Ex and no improvement.

      So i had this idea and I posted this before

      Bad or Burnt Exhaust smell in cabin during hard acceleration.



      and since then this idea never left my mind so what i did is i sealed the hood rubber with silicon filler underneath the rubber " all of it"

      [​IMG]

      and BOOM. i was shocked i would say 92% of the smell has gone ! but i had to confirm it

      so i posted this.

      And Mr

      Manuel Garcia

      Was ready to confirm my theory, he never done any TSB with the dealer and he was facing this issue a lot and the smell was very vey bad. so he sealed the engine rubber and guess what ? Yes it worked for him too.

      Almost the smell has gone. then we tried another thing, covering the fresh air intake with duct tape and it also worked even better than the silicon. but this is not a solution, we can't keep the duct tape covering the fresh air intake.


      Now lets explain this issue, basically there are two issues.

      1.Exhaust Leak from the engine side that will not appear unless there is a hard acceleration.
      2. Fresh Air Intake leaks.

      and what happen is while acceleration the engine bay gets filled by exhaust odors and the odors finds a way to leak inside cabin through Fresh Air intake.
      So anyone want to confirm this go ahead and cover your fresh air intake with duct tape

      [​IMG]

      then go for a ride and try

      Careful: the duct tape is not a solution, only to confirm this leak, when you use the duct tape don't run the A\C on non circulation that might damage the A\C fan.





      To solve this issue permanently, The whole Fresh Air intake plastic peace need to be take off then seal every whole in it from the engine side and seal the hood rubber with silicon . but for now the silicon is working fine.
       
      Last edited: January 3, 2018
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    3. KayGee

      KayGee Active Member

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      It seems to me that if exhaust gases are filling your engine bay and making their way into the fresh air intake, that would be indicative of an exhaust leak, such as a cracked manifold, gasket leak, or something similar, in the engine bay.

      Just a thought, but it may be "cleaner" to just use a double sided adhesive/foam tape to seal the rubber weatherstrip at the back edge of the hood.

      I don't think that is the same as the CO issue that the TSB is trying to address.
       
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    4. peterk9

      peterk9 Staff Member Moderator Elite Explorer

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      I'm tempted to go along with KayGee. I don't see how exhaust gases from the rear can enter the cabin from the front when the air flow is toward the rear when you're driving. Also, the work done in the TSB you had done in 2016 would not be the same as the work now being done with the latest bulletin.

      Peter
       
    5. Black Eyed

      Black Eyed Member

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      My Explorer has only 30K and i'm facing this issue since i bought it brand new. My point is i think the CO Inside cabin issue is there is a leak in the engine side - manifold which causing this issue.

      since the latest TSB 17-0044 didn't work with some people here. Ford should consider this.

      anyway. let's see what will happen when the members test their Ex with my idea.
       
    6. Black Eyed

      Black Eyed Member

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      of course the gases will not come from the rear back to the engine bay against the air flow. there is a leak in the engine bay which causing this issue.

      Even the latest TSB 17-0044 didn't work for some members here as i read in this post

      Ford offers free repairs to 1.4 Million Explorers - Exhaust
       
    7. Black Eyed

      Black Eyed Member

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      No one is interested to test this ?
       
    8. Manuel Garcia

      Manuel Garcia New Member

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      I did this in my vehicle, the ford with the tape is my 2015 xlt, is working 100%, all the people in the forum need to try this.
       
    9. 1995E

      1995E Well-Known Member

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      I'd try to report your findings to in the on going investigation. Leaking exhaust manifolds were common on Police Interceptors as well and Ford should deal with this issue as part of their TSB.
       
    10. Black Eyed

      Black Eyed Member

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      That’s great.

      But I already tried to report this to Ford with no luck. I would appreciate if you try.
       
    11. 1995E

      1995E Well-Known Member

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      Ford only has their best interest in mind. Go here: NHTSA
       
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    12. Tas246 Explorer

      Tas246 Explorer New Member

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      I just received the recall from ford last week. Does this not fix the issue on my 2015?
       
    13. reserved50

      reserved50 Well-Known Member

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      Fords not dumb, they probably have a few dozen engineers go over the issues. Whatever they release for whatever issue is up to them. I would buy a battery operated CO detector with a digital readout to confirm any findings.

      Instead of silicone I would have replaced the hood seal with a new one and tested the fit by sliding a feeler gauge under it etc. If there were any gaps I would use a thin automotive foam tape to make a tighter seal, maybe even use it on the hood side.

      The smell could be coolant venting also.
       
      Last edited: December 12, 2017
    14. Black Eyed

      Black Eyed Member

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      I never thought doing this, but i will

      thanks.
       
    15. Black Eyed

      Black Eyed Member

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      If you still having this issue you can try this to confirm where the leak comes from.
       
    16. Black Eyed

      Black Eyed Member

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      I don't think that replacing the hood rubber will do anything, sealing the rubber with silicone is better even for a water leak, sometimes when i wash the car i found little water drops above the engine rubber cover comes from the rubber side. but since the main issue is not from the rubber, Ford should investigate why there is an exhaust leak in the engine bay.
       
      Last edited: December 12, 2017
    17. Jon M

      Jon M Elite Explorer

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      Knowing that there have been cracked manifolds in PIUs, it wouldn't surprise me to find some in the Explorers as well, unless the cracks were only on 3.7s. I've had a couple of theories as to how it could be coming from the front, but I can't find anything on mine to confirm it.
       
    18. Black Eyed

      Black Eyed Member

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      After i sealed the hood rubber with the silicone i found another leak by spraying A\C refresher inside the Air Intake.

      since this leak from inside the Fresh Air intake, exhaust odors can leak inside through this leak point.
       
      Last edited: January 3, 2018
    19. Black Eyed

      Black Eyed Member

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      If this is true then Ford should check the mainfolds in the reported Explorers. the crack leaks odors to the engine cabin then leaks into the fresh air intake. there is no other explanation i guess.

      i need to go under my vehicle and check the mainfold.
       
    20. Black Eyed

      Black Eyed Member

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      May i ask to stick this thread to confirm from other members if they want to check their Explorers by sealing the rubber and covering the fresh air intake to confirm this ?
       
    21. Black Eyed

      Black Eyed Member

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      I Wouldn't be surprised if i found a crack in my exhaust manifold. I will consider this another prove to my theory.
       
    22. thefranchise713

      thefranchise713 Active Member

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      I had the smell in mine, but my manifold was specifically checked due to the issues in the PIU. It was 100% fine. Regardless, after hitting the entire car with sealer, the problem is fixed.
       
    23. Black Eyed

      Black Eyed Member

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      So this another confirmation to my theory. the cracked manifold filled the engine bay with exhaust smell that finds their way through the fresh intake to the cabin.
       
    24. thefranchise713

      thefranchise713 Active Member

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      Keep in mind, I was confirming that my manifold was not cracked or flawed. The car was sealed up especially well in the back end, not the front.
       
    25. Odrapnew

      Odrapnew Active Member

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      Thanks for clarifying the sealing. I was going to ask what you had done.

      Also, was it just the standard Ford fix that you had done(the dealer repairs)? Or did you do more or other sealing?
       
    26. thefranchise713

      thefranchise713 Active Member

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      Dealer performed the TSB at the time, but also did their own efforts of going at every possible source of a leak, TSB or not (this was before the latest revision, mind you, but there were revised parts available.) At the time the field service engineer was involved for that and a few other simultaneous issues. The back end of the car came apart a couple of times.
       

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