Exhaust smell inside 2021 BS Badlands

Ssabin

Outer Banks
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Scott
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I too had a cracked catalytic converter. The smell was noticeable for a couple months before it got obnoxious/dangerous. Over Thanksgiving, my wife warmed up the BS and the dogs had piled in fear we would leave them, and when I opened the door to load some things, I thought we were trying to kill our dogs.

Took it into the dealership and explained what I knew about this issue after reading this thread. They called back and said I had both a cracked catalyst and a leaky water pump. They replaced both under warranty, and had perhaps my best dealership experience in a long while.

Just drove it home from the dealership and the lack of the exhaust smell was indeed something I noticed!

The only code I had in my PCM was a P04F0, which is either a phantom code, or an unrelated problem. I'm hoping the recall work on the PCM/BCM update might also address the fuel vapor diagnostic, but we'll see. If the P04F0 comes back, I'll have to pick up a purge valve/hose assembly and assume that will resolve it.
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Smurf007

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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?
I had this problem in my 2021 BB Bronco. Ford couldn't figure it out, so they ended up taking my 2021 big ben bronco, and swapping it out with a 2022 BB Bronco. Now I'm having the same problem with this one. I honestly think I'm gonna be getting rid of the Bronco completely. As much as I love the vehicle. This is two Broncos in a row now where I've had exhaust leaks come inside and they don't know what's going on
 

kshirley47553

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I had this problem in my 2021 BB Bronco. Ford couldn't figure it out, so they ended up taking my 2021 big ben bronco, and swapping it out with a 2022 BB Bronco. Now I'm having the same problem with this one. I honestly think I'm gonna be getting rid of the Bronco completely. As much as I love the vehicle. This is two Broncos in a row now where I've had exhaust leaks come inside and they don't know what's going on
it’s the catalytic converter. They’re trash. Mine went out at 25k. I had to leave it overnight and let them cold start it. Tell them there’s a rattle under the gas pedal when you accelerate - sounds like a pebble in a tin can. I didn’t even realize it was a bad noise until they replaced my cat and the noise is gone. It took me 2 months and 5 trips. Just keep harassing them!
 

Charlie Horse

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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!

Hello

I have had this same issue with the exhaust oder within the cabin. The catalytic converter was replaced because of a crack that had developed. Issue resolved.
 

Charlie Horse

Big Bend
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I had this problem in my 2021 BB Bronco. Ford couldn't figure it out, so they ended up taking my 2021 big ben bronco, and swapping it out with a 2022 BB Bronco. Now I'm having the same problem with this one. I honestly think I'm gonna be getting rid of the Bronco completely. As much as I love the vehicle. This is two Broncos in a row now where I've had exhaust leaks come inside and they don't know what's going on

Hello

I had the same issue with my Big Bend. The catalytic converter was replaced and resolved the issue.
 


PCCLP

Big Bend
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This seems to be a problem with the Bronco Sport. Taking my '21 Big Bend in, again, on Monday. Second time to the dealer regarding the exhaust smell in the cabin. Hoping for a fix this time.
 

Shananigans

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Got an exhaust leak. Just over 80k. The smell reeks.

Found the crack just behind the front clamp on the front cat. Hard to see but the split is just above the nut in the pic.

Ford Bronco Sport Exhaust smell inside 2021 BS Badlands PXL_20250419_170009809
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