Bad or Burnt Exhaust smell in cabin during hard acceleration.

[Hazegray]

So far, so good!

Well it has been nearly 2 months since I got the XLT back. The smell seems to be gone (although I think I get a nasal flashback every once in a while but my wife says I'm crazy!). The 20,000 mile service is coming up and I will have the guys sample the PTU fluid. No issues with power train or changing to snow covered roads. We had 10~12" of snow a few weeks back, no problems.

Clearly there are two issues here. The exhaust issue for which there is the TSB and the seemingly rare PTU issue. I don't know if my story belongs on this thread or should have its own but I'll leave it here for now.

I will let you know if the PTU fluid sample is a problem. No news is good news.

(Hmmm....I think its time to get rid of the Uplander....which Ford to choose?)

 

[FordService]

Well it has been nearly 2 months since I got the XLT back. The smell seems to be gone (although I think I get a nasal flashback every once in a while but my wife says I'm crazy!). The 20,000 mile service is coming up and I will have the guys sample the PTU fluid. No issues with power train or changing to snow covered roads. We had 10~12" of snow a few weeks back, no problems...

Awesome news, Hazegray! Keep us posted, and if you ever need my assistance, I'll be here!

Crystal

 

[Kesha]

Hi,
I have delivered my car to technical department in UAE, Dubai, Al Tayer Motors to solve this problem and left for 2 days. While taking back I had no chance to check car because all technical staff went to home (it was 18:00), only service advisor. But problem still continue, still smells
Kazhi

 

[machine4321]

I too have notices the smell. But only when the roof is open or windows are slightly open. There must be a slight vaccume that draws it in. I I can get it to replicate at will I will have to take it in.

 

[jrmexplorer]

This is how the Jeep guys solved this problem:

by not staying between the lines while parking?

 

[FordService]

I too have notices the smell. But only when the roof is open or windows are slightly open. There must be a slight vaccume that draws it in. I I can get it to replicate at will I will have to take it in.

Good idea, machine4321. Let us know how your visit goes.

Crystal

 

[tnt_12]

machine4321, you are right, it does come in the windows. Around here I leave the A/C and heating system off all winter and with the windows closed I never get the exhaust in the car. If I open the windows and accelerate onto the highway, exhaust comes into the car. Yikes, it might be coming in these cars from the back and the windows.

 

[Dark_Phoenix]

Brought in my EX to (Al Tayer Motors - Ford UAE) workshop awhile ago (1st service, 6 months, at 8,200kms / around 5k+ miles). I raised my concern regarding unpleasant smell during hard acceleration and the service agent took note of it, he will keep me posted later on today. He told me that I am his first customer to have this issue. Let us see and will post update soon.

update
Got back my EX! TSB to be done for the unpleasant smell when the parts arrive hopefully in 30days. SA admitted at the end that he knew the issue beforehand but he cannot say anything until their expert technicians check the EX. He told me instead that if I knew someone with this issue, ask them to bring their EXs to the workshop to address the issue asap.

 

[Concerned2012]

Well Al Tayer Motors are lying to you. I have taken my Explorer twice for this issue. They even performed the TSB. But nothing worked. You are surely not the first one to complain. Ask the test drivers there and they are so familiar with the smell that they don't even want to take a test drive before confirming the smell.

 

[Dark_Phoenix]

Well Al Tayer Motors are lying to you. I have taken my Explorer twice for this issue. They even performed the TSB. But nothing worked. You are surely not the first one to complain. Ask the test drivers there and they are so familiar with the smell that they don't even want to take a test drive before confirming the smell.

I totally agree with you. When he told me that I was his 1st customer, what was running on my mind was 'this is just protocol answer to all complaining customers.' And when he did not bother to ask me for a test drive to confirm the smell, 'twas a clear manifestation that I am not the 1st one.
If after the TSB will be performed and the issue will still be there, I will be forced to let go of our EX asap.

 

[jamers99]

I'm curious if Ford has made production changes to correct this issue? My Explorer Sport was produced in March 2013. I have yet to take delivery. I wonder if I should expect to have this issue?

 

[ACREYMAN]

So I just bought a 2013 XLT (LOVE IT!) and dismissed the smell as a "break in" smell till I stumbled on this. Yep, hard to baby this thing when entering the highway and that is when I notice the smell so appointment pending.

I also noticed some guys boasting about KIA and Hyundai.....ok I just traded my 2011 KIA Sorento in for this Ford and the Sorento cant touch this thing. It was not a BAD car by any means but the cheap parts and design flaws start to pop out at you after a few thousand miles. Don't get me started on the poor ventilation in the rear seats, the Ford has vents all over the back and my kids can stay warm or cool in this Texas weather no problem even in the third row. Also the little four banger was a mistake. At 70mph with four occupants the car got, at best, 23mpg. Add camping gear and I averaged 20mpg on a 4000 mile trip (far form the advertised 29mpg hwy and I was not traveling more than 70) I noticed already the Ford thrives at the advertised 25hwy at 70mph and I was getting 24 with it geared down the other day. So this truck gets better hwy MPG than the KIA even though the KIA is advertised higher. Don't be fooled by the MPG stats of that little engine, it just could not handle it. Good for picking up the kids from school but that's about it, plus long trips in that very uncomfortable seat (plus me complaining about the bad gas mileage)....love the seat in this thing

 

[esw2005]

The smell is gone!! 6900 miles later

 

[Toddgfd]

Finally get it in to the dealer for the TSB... Service mgr. said it is leaking fluid from the PTU. They fixed the seal, and did NOT perform the TSB, period.

Drove it a few days, and noticed the burning smell even driving normal (not hard acceleration). I think there was an amount of fluid still burning off the exhaust...

Seems ok now, but I got a feeling around summertime when I turn on the A/C, its gonna start to smell like burning oil again.... cant wait.

-ern

Hey ern3,

What did your exhaust pipes look like? The one on the driver's side on mine just forward of the catalytic convertor is coated with black pungent stains. The area just above is soaked with clear fluid a little more viscous than motor oil, drips in the driveway as well. I am at the dealer right now waiting for a diagnosis.

 

[Toddgfd]

Diagnosis Complete

Ok, the dealer officially has my 1 week old X Sport with 300 miles on it. The cause of the stink? Blown PTU. It leaked the gear oil onto a pan next to it and dispersed the oil along one of the 2 exhaust pipes forward of the catalytic converter, causing the oil to smolder and create smoke (though I never saw any) in the engine compartment. The stink was then assumedly brought in to the cabin from the rear where others needed TSB addressed, or through the front intake when we stopped (the cabin filter would not be able to stop odors). The service team at South Bay Ford in Los Angeles have been awesome. Great facility, attentive service manager that crawled under the car after I showed him some pictures, Free food coupons at a real on site restaurant, and a rental car. They said that it will take a week to complete repairs. I stressed the importance of replacing the contaminated exhaust pipe, and he indicated that they will need approval to either "CLEAN" it, or what I indicated is my only acceptable option "REPLACE" that section. I am happy that they found the problem and are confident that the repairs will completely solve it.

 

[jamers99]

What does PTU stand for anyway?

 

[Toddgfd]

What does PTU stand for anyway?

It's the Power Transfer Unit that works with the computer to apply different torque ranges between the front and rear wheels.

 

[peterk9]

Ok, the dealer officially has my 1 week old X Sport with 300 miles on it. The cause of the stink? Blown PTU. It leaked the gear oil onto a pan next to it and dispersed the oil along one of the 2 exhaust pipes forward of the catalytic converter, causing the oil to smolder and create smoke (though I never saw any) in the engine compartment. The stink was then assumedly brought in to the cabin from the rear where others needed TSB addressed, or through the front intake when we stopped (the cabin filter would not be able to stop odors). The service team at South Bay Ford in Los Angeles have been awesome. Great facility, attentive service manager that crawled under the car after I showed him some pictures, Free food coupons at a real on site restaurant, and a rental car. They said that it will take a week to complete repairs. I stressed the importance of replacing the contaminated exhaust pipe, and he indicated that they will need approval to either "CLEAN" it, or what I indicated is my only acceptable option "REPLACE" that section. I am happy that they found the problem and are confident that the repairs will completely solve it.

Glad they found the issue and are fixing it. I personally wouldn't get to worked up about replacing the exhaust pipe. It is only external discolouration and should not affect the pipe at all. Any odour causing fluids should burn off.

Peter

 

[FordService]

Ok, the dealer officially has my 1 week old X Sport with 300 miles on it. The cause of the stink? Blown PTU...

Thanks for the update, Toddgfd. Keep us posted on how things progress at the dealership. If you need any additional assistance from me, just let me know.

Crystal

 

[JohnBoyToo]

I too wouldn't be too worried about the exhaust ...

The fluid may actually protect the pipe for a while