Exhaust coming into cab - Warranty repair issues - No assistance from Ford

[Dt45]

2022 Ford Bronco Sport 35k miles roughly. On November 1st I realized I had exhaust coming into my cab from the vents. It was really strong. Started burning my eyes and effecting my health. I called the dealer and brought it in for warranty repair. They did not help me with a loaner vehicle or rental. They had it for about 6 days and stated it was an exhaust clamp and gave it back to me. They struggled to find the leak during the time they had the vehicle per the service rep. I received it back and realized the exhaust is still coming into the cab. I called the dealership back and stated I need to bring it back because I couldn't drive it like that. I dropped it back off and they had my vehicle until 11/29/2023. During this time, I was told that they can't find the leak. No assistance with a loaner or rental vehicle. Had to find forms of transportation and places to stay just to get to work. Had to purchase a plane ticket during Thanksgiving due to not being able to drive to my destination and more. When they called me about the car being fixed, they stated that they had to change another exhaust clamp. At this point, they have had my car for about 28 days. After I picked it up and drove it a little I realized the exhaust was still coming into the cab. I called the dealership to have it dropped off for a 3rd repair. They had my car for another 12 days of not being able to utilize my vehicle. They replaced the catalytic converter due to a crack. I picked up the car yesterday. Corrected repair TBD.

I contacted Ford Customer Service during this process. They did not offer assistance during this time. They stated that the car needs to have a diagnoses before rental vehicle assistance can be given. The dealership failed to diagnose the car correctly multiple times and took over 30 days to come to diagnose. Due to the dealership giving my car back twice not repaired, Ford Customer Service stated they couldn't assist me because the car wasn't at the shop for a certain amount of consecutive days.

I love my Bronco Sport but I never thought I would have such a hard/rough time with warranty work and no assistance for over a month.

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[Mark S.]

You may have a good case for a Lemon Law claim. Most lawyers offer a free initial consult to determine if you have a case.

 

[jason202]

A representative from Ford sometimes shows up on here, but from all I've heard, they don't really offer much in terms of tangible assistance.

 

[MJbronco]

A representative from Ford sometimes shows up on here, but from all I've heard, they don't really offer much in terms of tangible assistance.

They don't! Reached out for some warranty stuff, took my VIN and heard nothing back since then....OPs concern is legitimate. For the dealership to take your car for that long for warranty related issues and not receive a loaner vehicle is ludicrous

 

[petegee77]

They don't! Reached out for some warranty stuff, took my VIN and heard nothing back since then....OPs concern is legitimate. For the dealership to take your car for that long for warranty related issues and not receive a loaner vehicle is ludicrous

Couldn't agree more. TERRIBLE service or should I say NON service. Mark hit the nail on the head. Check out your states lemon law. I really HATE hearing things like this. It reflexs so poorly on Ford itself. My BSBB only has 8800 miles on it but when it hits the 3 yr mark and is off warrenty I'm thinking right now it's a goner.

 

[Ford Motor Company]

2022 Ford Bronco Sport 35k miles roughly. On November 1st I realized I had exhaust coming into my cab from the vents. It was really strong. Started burning my eyes and effecting my health. I called the dealer and brought it in for warranty repair. They did not help me with a loaner vehicle or rental. They had it for about 6 days and stated it was an exhaust clamp and gave it back to me. They struggled to find the leak during the time they had the vehicle per the service rep. I received it back and realized the exhaust is still coming into the cab. I called the dealership back and stated I need to bring it back because I couldn't drive it like that. I dropped it back off and they had my vehicle until 11/29/2023. During this time, I was told that they can't find the leak. No assistance with a loaner or rental vehicle. Had to find forms of transportation and places to stay just to get to work. Had to purchase a plane ticket during Thanksgiving due to not being able to drive to my destination and more. When they called me about the car being fixed, they stated that they had to change another exhaust clamp. At this point, they have had my car for about 28 days. After I picked it up and drove it a little I realized the exhaust was still coming into the cab. I called the dealership to have it dropped off for a 3rd repair. They had my car for another 12 days of not being able to utilize my vehicle. They replaced the catalytic converter due to a crack. I picked up the car yesterday. Corrected repair TBD.

I contacted Ford Customer Service during this process. They did not offer assistance during this time. They stated that the car needs to have a diagnoses before rental vehicle assistance can be given. The dealership failed to diagnose the car correctly multiple times and took over 30 days to come to diagnose. Due to the dealership giving my car back twice not repaired, Ford Customer Service stated they couldn't assist me because the car wasn't at the shop for a certain amount of consecutive days.

I love my Bronco Sport but I never thought I would have such a hard/rough time with warranty work and no assistance for over a month.

Hey there! If you send over a DM with your VIN and Ford dealer info, I can look into your concerns on my end.

 

[toddedmond]

I copied and pasted this on another related post:
I have the same problem on my '21 OBX. Exhaust smell in cabin when idling. I can make it quit by pushing the Recirculate button on the climate control. Don't smell it when moving. I just picked it up from a second dealer. First dealer, where i bought it from said they didn't notice it. Second dealer says they smell it, but find no exhaust leaks. They tried to blame it on my K&N filter oil. I don't know where to turn next. Any ideas?

 

[Mark S.]

They tried to blame it on my K&N filter oil.

I'm sorry, are you saying they are blaming a potential exhaust leak on your choice of oil filter?

 

[Escape2Bronco]

I think it sounds more like a stuck cabin pressure relief valve. I’m pretty sure they are located either in the tailgate or one of the rear corners. That might explain the exhaust smell this early in the vehicle life cycle.

 

[Escape2Bronco]

I'm sorry, are you saying they are blaming a potential exhaust leak on your choice of oil filter?

I think he is talking about the oil used on the K&N air filter but I’m not aware of this being used on the cabin filters. It is used on the engine air filters.

 

[toddedmond]

They did blame it on the cabin filter. I have a K&N and you are correct, it is not oiled.

 

[toddedmond]

To humor them, I put the normal paper type back in for the cabin and engine filters. Haven't driven it since I did that last night. I don't think it will make a difference.

 

[toddedmond]

I might have found the source, and it was self inflicted. A couple months ago I adjusted the rubber bumpers on the lift gate out. I adjusted them back where they were yesterday and it dramatically reduced the smell. I think I inadvertently messed up the seal and the exhaust was coming in through the lift gate seals when I was sitting still. Lesson learned.

 

[Amy E]

2022 Ford Bronco Sport 35k miles roughly. On November 1st I realized I had exhaust coming into my cab from the vents. It was really strong. Started burning my eyes and effecting my health. I called the dealer and brought it in for warranty repair. They did not help me with a loaner vehicle or rental. They had it for about 6 days and stated it was an exhaust clamp and gave it back to me. They struggled to find the leak during the time they had the vehicle per the service rep. I received it back and realized the exhaust is still coming into the cab. I called the dealership back and stated I need to bring it back because I couldn't drive it like that. I dropped it back off and they had my vehicle until 11/29/2023. During this time, I was told that they can't find the leak. No assistance with a loaner or rental vehicle. Had to find forms of transportation and places to stay just to get to work. Had to purchase a plane ticket during Thanksgiving due to not being able to drive to my destination and more. When they called me about the car being fixed, they stated that they had to change another exhaust clamp. At this point, they have had my car for about 28 days. After I picked it up and drove it a little I realized the exhaust was still coming into the cab. I called the dealership to have it dropped off for a 3rd repair. They had my car for another 12 days of not being able to utilize my vehicle. They replaced the catalytic converter due to a crack. I picked up the car yesterday. Corrected repair TBD.

I contacted Ford Customer Service during this process. They did not offer assistance during this time. They stated that the car needs to have a diagnoses before rental vehicle assistance can be given. The dealership failed to diagnose the car correctly multiple times and took over 30 days to come to diagnose. Due to the dealership giving my car back twice not repaired, Ford Customer Service stated they couldn't assist me because the car wasn't at the shop for a certain amount of consecutive days.

I love my Bronco Sport but I never thought I would have such a hard/rough time with warranty work and no assistance for over a month.

 

[Amy E]

Was the issue fixed after catalytic converter was replaced

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