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    Bad or Burnt Exhaust smell in cabin during hard acceleration.

    I am surprised Ford made this refund offer, but now that it has, I advise anyone concerned about CO exposure to test their vehicle ASAP and request a refund if CO goes over 5ppm (This is the only CO limit for vehicle interiors. It was adopted by Russia in 2004, which is one of just 3...
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    Bad or Burnt Exhaust smell in cabin during hard acceleration.

    So that just leaves the rear door seal to replace. That alone could be the problem, or more likely, the dealer didn't do all the recommended sealing of seams and holes. To see if you can reproduce the odor, I suggest trying acceleration with HVAC recirculate ON instead of in automatic.
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    Bad or Burnt Exhaust smell in cabin during hard acceleration.

    Sorry to hear the first fix didn't work. Can you tell us how fast you were going when you noticed the odor again, and if AC was on recirculate or off? Since Ford didn't replace your exhaust manifold, rear door seal or exhaust tips, I suggest you try asking for these repairs next.
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    Exhaust leaks, Ford Explorers and the environment.

    In class action settlement , Ford agreed to pay for $150 worth of phase 1 repairs and if customer remains unsatisfied (!), another $500 for phase 2 repairs including new exhaust parts. After that, if you are still unsatisfied, Ford agrees not to contest if you file a complaint via your state's...
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    U.S. Expands Probe Into Ford Explorers Over Carbon Monoxide Concerns

    If you add the Ford Pinto to your list, my suggestion is not so far fetched. I also hope I am wrong, but either way, Ford now has a much bigger problem than if they'd taken this seriously in 2011 when it was first reported.
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    U.S. Expands Probe Into Ford Explorers Over Carbon Monoxide Concerns

    I agree that Kay raises an important question, and the most obvious place to look for similar problems would be from the Chicago plant where the Explorers are assembled. According to Wikipedia, the plant also makes Taurus and Lincoln MKS. Both are large sedans with long trunks-- but without...
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    Exhaust leaks, Ford Explorers and the environment.

    Human sense of smell varies widely, with the threshold of detection for any particular odor typically ranging over 2 to 3 orders of magnitude. Also highly variable is how long it takes people to get desensitized to any particular odor (to go nose blind). Human odor detection threshholds...
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    U.S. Expands Probe Into Ford Explorers Over Carbon Monoxide Concerns

    You would think Ford would have fixed such obvious design and assembly flaws sooner, but what if Ford deliberately made the choice not to in the early years (before the NHTSA investigation opened) as the result of some cost benefit analysis? Sealing seams and holes correctly takes a lot of...
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    U.S. Expands Probe Into Ford Explorers Over Carbon Monoxide Concerns

    I agree that CO may be leaking from a cracked manifold or just from the tailpipe, but either way it is entering the vehicle via the many holes and seams that Ford left unsealed around the rear end and underbody. if the CO leak is at the manifold prior to the catalytic converter, the CO level...
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    Exhaust leaks, Ford Explorers and the environment.

    Ford's proposed repairs for exhaust odor complaints in the PIU and civilian Explorers are the same, as detailed most recently in TSB17-0044 at http://www.mhq.com/wp-content/uploads/2017/08/TSB-17-0044-Exhaust-Odor-in-Vehicle.pdf Dealers are supposed to visually inspect and add sealant as...
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    Carbon Monoxide Leak?

    Ford's PR Department has been sending the message that CO leaks occur only in PIU's where they are caused by aftermarket add-ons and upfitting that leave holes unsealed in the body. But Ford's latest TSB 17-0044 on fixing odor leaks specifies 16 pages of other repairs, most of which involve...
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    Testing Ford Explorers and their drivers for Carbon Monoxide

    I filed a petition with NHTSA in 2000 requesting that manufacturers be required to hardwire cabin CO alarms into all their vehicles, to provide some early warning at low levels of exposure and to shut down the engine at high levels (only if not moving of course, such as in a garage) in order to...
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    U.S. Expands Probe Into Ford Explorers Over Carbon Monoxide Concerns

    The CO level inside a vehicle should be no more than outside, which is usually <1ppm except in heavy traffic, tunnels or garages when the air around your vehicle may have 5-35 ppm. You cannot rely on EPA's average outdoor limits of 9 ppm over 8 hours and 35 ppm over 1 hour because these were...
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    Testing Ford Explorers and their drivers for Carbon Monoxide

    I stand corrected. Kidde does sell one model of CO "Monitor" (KN-COU-B) http://www.kidde.com/home-safety/en/us/products/fire-safety/co-alarms/kn-cou-b/ --in contrast to 16 models of home CO "Alarms" http://www.kidde.com/home-safety/en/us/products/fire-safety/co-alarms/ --that displays the CO...
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    Bad or Burnt Exhaust smell in cabin during hard acceleration.

    That sure was a long test drive! Good to know Ford's TSB 17-0044 can stop exhaust odor in some cases. Can you tell us if your repair included replacing the exhaust manifold, the exhaust pipe tips, or the rear door seal?
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    Bad or Burnt Exhaust smell in cabin during hard acceleration.

    Obviously a QC issue, given that most of the resealing recommended in tsb17-0044 is supposedly recognizable by visual inspection.. (And so should have been caught during production). I have measured 0ppm under similar conditions in an Expedition and an Escape but that does not mean they are...
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    Bad or Burnt Exhaust smell in cabin during hard acceleration.

    I checked both with recirculate on and off. The measurements I reported above were the peaks seen during continuous monitoring with recirculate on. Within a few minutes of turning recirculate off, the CO level falls to <3ppm (but you have to keep fan on high)
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    Bad or Burnt Exhaust smell in cabin during hard acceleration.

    CO level rises when AC is ON and recirculate is ON (no dilution) and falls when recirculate is OFF (max dilution). The problem is not caused by exhaust coming in the fresh air vents, but rather by exhaust coming in through insufficiently sealed seams and holes all around the back hatch, under...
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    Bad or Burnt Exhaust smell in cabin during hard acceleration.

    So far I have checked only 3, but CO was over 20ppm in all of them (all unmodified), vs CO in ambient air less than 1ppm. As for professional portable CO detectors that can display accurately from 1ppm, anything you can find via Google in the $100 to $300 range should be sufficiently...
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    Bad or Burnt Exhaust smell in cabin during hard acceleration.

    Sorry this wasn't clear. The worst case of CO intrusion that is consistently reproducible occurs when already over 45mph and then accelerating with WOT, as when merging onto a highway, or when accelerating to pass. There is no need to test WOT from zero.
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    Explorer Carbon Monoxide CO Detector Install

    The information on CO levels being quoted here from https://www.kane.co.uk/knowledge-centre/what-are-safe-levels-of-co-and-co2-in-rooms is incorrect. The OSHA CO limit is 50ppm average over 8 hours, not 35ppm. And 9ppm is both ASHRAE max and EPA average. 35ppm is the level at which...
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    Bad or Burnt Exhaust smell in cabin during hard acceleration.

    I am toxicologist who joined this forum so I can share information on how to measure carbon monoxide (CO) levels in Ford Explorers and the drivers of Ford Explorers. #1. If you can smell an exhaust odor, odorless CO is also present, but CO may be present even if you do not smell exhaust, or...
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    Testing Ford Explorers and their drivers for Carbon Monoxide

    I am toxicologist who joined the forum so I can share information on how to test carbon monoxide (CO) levels in Ford Explorers and the drivers of Ford Explorers. #1. If you can smell vehicle exhaust, odorless CO is always also present, but CO may be present even if you do not smell exhaust...
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