Exhaust smell inside 2021 BS Badlands

[Bucko]

But do you hearing groaning sounds when walk backwards?

Yes, that would be the wife complaining, and informing me "no more pinto beans for you".

Sponsored

 

[toddedmond]

Update:

I am now part of the Cracked Cat Converter club. I started getting exhaust smell in the cabin about six months ago. I could lessen it by putting the climate control into recirculate mode. That was not a good remedy because recirc times out.

I took it in to the dealer for an unrelated issue and asked them to also check for an exhaust leak. They claimed to not be able to duplicate the probem, even though everyone who rode with me commented on the smell.

A month or so later, I took it to a different dealer for a second opinion. Thier diagnosis was ridiculous, they blamed it on me having K&N engine and cabin filters. They then sprayed some kind of deodorizer in my vents and sent me on my way.

About a month ago, along with the smell, I started to notice my exhaust getting louder on cold startup and under load.

I could feel exhaust air when feeling around the turbo area. I then took it back to the original dealer telling them what I found. They determined it to be a cracked cat, ordered the parts, and three days later replaced it.

It is now fine, no smell or loud noise. What could cause a catalytic converter to crack on a vehicle with only, at the time 42000 or so miles on it? I have never had that happen on any vehicle I have ever had.

 

[Mark S.]

What could cause a catalytic converter to crack on a vehicle with only, at the time 42000 or so miles on it?

All production parts have a given failure rate. The catalytic converter in your car likely had a production flaw that required a certain number of heating/cooling cycles to manifest.

 

[Bluesteelworx]

Mine just started having this same issue a few months ago. I’m currently at 52000 miles. Took the vehicle in for the injector recall, coolant loss once again and now exhaust smell. I used to have a 2014 ford flex with a similar issue. Would smell like exhaust once you get on the accelerator. Bronco sport smells when idling and ac/heater on. I’m surprised how many issues I’ve had with such low mileage. I’m really starting to consider getting rid of it now before it’s out of warranty and probably won’t ever get another ford again.

I had my coolant pump replaced twice within first 20k, exhaust smell started after recall at 25 or 30k

 

[21Broncosaurus]

Took vehicle in for exhaust smell in cabin. Dealer called back and said catalytic converter needs to be replaced.

 

[Westernplatypus]

I’m having this same issue! It’s been in 3 times. The first time, she thought it was burning coolant, but was unable to fix it. The second time, they couldn’t recreate it despite us explaining it needs to be drive stop and go since it happens when stopping (I doubt they even drove it!). The third time, I had the shop foreman drive with me and he said it was definitely exhaust. He then told us he couldn’t find the issue and couldn’t fix it. We will take it in again to two different dealerships and have them drive with us. It’s so frustrating because I can’t drive the car without getting a headache from this, so I’ve been sharing a car with my husband. My car only has 10,000 miles and has been in the shop for at least a month total for this same issue. So frustrating!!!

 

[BLUEOVALRACER]

I’m having this same issue! It’s been in 3 times. The first time, she thought it was burning coolant, but was unable to fix it. The second time, they couldn’t recreate it despite us explaining it needs to be drive stop and go since it happens when stopping (I doubt they even drove it!). The third time, I had the shop foreman drive with me and he said it was definitely exhaust. He then told us he couldn’t find the issue and couldn’t fix it. We will take it in again to two different dealerships and have them drive with us. It’s so frustrating because I can’t drive the car without getting a headache from this, so I’ve been sharing a car with my husband. My car only has 10,000 miles and has been in the shop for at least a month total for this same issue. So frustrating!!!

Has the BS been wrecked? I watched a Video of a Ford Explorer IIRC and they had many people looking for an exhaust leak they could smell it inside like you. Finally a Mechanic noticed a larger gap on one side of the rear hatch than the other side and sure enough the exhaust was coming in from the rear hatch from the hatch being tweaked.

 

[Nam3]

Update:

I am now part of the Cracked Cat Converter club. I started getting exhaust smell in the cabin about six months ago. I could lessen it by putting the climate control into recirculate mode. That was not a good remedy because recirc times out.

I took it in to the dealer for an unrelated issue and asked them to also check for an exhaust leak. They claimed to not be able to duplicate the probem, even though everyone who rode with me commented on the smell.

A month or so later, I took it to a different dealer for a second opinion. Thier diagnosis was ridiculous, they blamed it on me having K&N engine and cabin filters. They then sprayed some kind of deodorizer in my vents and sent me on my way.

About a month ago, along with the smell, I started to notice my exhaust getting louder on cold startup and under load.

I could feel exhaust air when feeling around the turbo area. I then took it back to the original dealer telling them what I found. They determined it to be a cracked cat, ordered the parts, and three days later replaced it.

It is now fine, no smell or loud noise. What could cause a catalytic converter to crack on a vehicle with only, at the time 42000 or so miles on it? I have never had that happen on any vehicle I have ever had.

Mine recently started having the same issues. At first it was just the smell and mostly while idling. A couple weeks ago it started getting really loud during start up idle. I actually kind of like the way it sounds, but the smell inside is worse. it also goes away when the AC in in recirculation mode. I'm at 44k miles. Will this be under warrenty? I hate the Ford Dealership so much I'm tempted to just pay a shop to do it since Ford will likely keep my car hostage for a couple weeks and I'll have to rent a car anyway.

 

[toddedmond]

Mine recently started having the same issues. At first it was just the smell and mostly while idling. A couple weeks ago it started getting really loud during start up idle. I actually kind of like the way it sounds, but the smell inside is worse. it also goes away when the AC in in recirculation mode. I'm at 44k miles. Will this be under warrenty? I hate the Ford Dealership so much I'm tempted to just pay a shop to do it since Ford will likely keep my car hostage for a couple weeks and I'll have to rent a car anyway.

Mine was covered, but I also have an extended warranty to 100000 miles. Pretty sure it will be covered under emissions.
Ford's emissions warranty covers parts that reduce emissions from a vehicle's engine. The warranty period varies by vehicle type and the parts covered:

• Passenger cars and light duty trucks: The emissions defect warranty lasts for eight years or 80,000 miles, whichever comes first. The emissions performance warranty lasts for eight years or 80,000 miles for the catalytic converter, electronic emissions control unit, and onboard emissions diagnostic devices, and two years or 24,000 miles for all other covered parts.
  
  
  
• Heavy duty vehicles: The emissions defect warranty lasts for five years or 50,000 miles, whichever comes first.
  
  
  
• Medium/heavy duty trucks over 10,000 pounds GVWR: The noise emissions warranty applies to these vehicles.
  
  

The emissions warranty guarantees that a vehicle's emissions control systems meet federal and state emissions requirements. To be covered under the emissions performance warranty, a vehicle must be maintained and operated according to the instructions in the owner's guide.


If a vehicle needs warranty repairs, it can be taken to the selling dealer or another Ford Motor Company dealership authorized for warranty repairs. Not all dealers are authorized to perform all warranty repairs.

 

[Ford Motor Company]

Mine recently started having the same issues. At first it was just the smell and mostly while idling. A couple weeks ago it started getting really loud during start up idle. I actually kind of like the way it sounds, but the smell inside is worse. it also goes away when the AC in in recirculation mode. I'm at 44k miles. Will this be under warrenty? I hate the Ford Dealership so much I'm tempted to just pay a shop to do it since Ford will likely keep my car hostage for a couple weeks and I'll have to rent a car anyway.

Good morning! I would be glad to help you out with this smell concern should you need further assistance. Just shoot us a direct message with your VIN and dealer name/location, and I'll get right on it. To send a direct message, just click on our username and select "Send Direct Message". Thank you!

 

[Mwittke5857]

I just bought a 2021 BS Badlands with 30K miles. Beautiful condition and runs great. I love everything about this car … except the occasional smell of exhaust?? that is finding its way into the cabin interior. I’m sure that any stickers or whatever have long ago burned off so I know that’s not the issue. I’m thinking that the catalytic converter may be fouled or there is some kind of exhaust leak. Before I start chasing this thing. I thought I’d check here for advice. I want a clean smelling car!

Had a similar situation, but only when idling more than 5 or so minutes. Being a "mod-a-holic", the second mod I did on my rig (the 1st was an afe intake) was a Flowmaster FX muffler. Never had an exhaust smell issue after that. I "think" it may have been due to the fact that the exhaust tips extend farther under the bumper than the stock ones did. Might be a seal issue for the liftgate, maybe an inherent design flaw as your not the 1st on the forum with this complaint. I also believe somewhere under there are "flapper valves" for cabin air circulation. This might be where fumes are infiltrating as well.

 

[Jack62748]

My 2022 OBX 37K miles is in the shop today for exhaust smell in cabin. Dealer called back and said catalytic converter and I need the water pump replaced (2nd water pump). I have the extended 100k warranty, I think all will be covered, rental car as well. I hope.

 

[Nam3]

I have officially been diagnosed with a cracked catalytic converter. The part is 6 days out but they let me take it home while I wait. They offered a rental up to 10 days but it seemed easier to drive my own. They are also doing the battery recall I've been ignoring. This will be my 5th recall, plus the cracked cat.

I almost traded this is for a ranger on Carvana a month or so ago. I still might.

 

[kshirley47553]

My 2022 OBX 37K miles is in the shop today for exhaust smell in cabin. Dealer called back and said catalytic converter and I need the water pump replaced (2nd water pump). I have the extended 100k warranty, I think all will be covered, rental car as well. I hope.

Did this fix the smell?

 

[Jack62748]

Yes, replacing the cracked catalytic converter fixed the exhaust smell coming from the vents

Sponsored