US regulators probe Ford Explorer SUVs over exhaust leak complaints
NHTSA is investigating 2011–2015 Ford Explorer SUVs after more than 150 complaints of exhaust odours inside the cabin, with concerns raised about possible carbon monoxide exposure.
The National Highway Traffic Safety Administration (NHTSA) has opened an investigation into 2011 to 2015 Ford Explorer SUVs following 154 owner complaints of exhaust odours entering the cabin. Some drivers have raised concerns about possible exposure to carbon monoxide, according to the agency.
The NHTSA said the complaints describe occupants noticing exhaust smells when the vehicle is under heavy acceleration, such as climbing hills, merging onto motorways or when the air conditioning is set to recirculation. One crash was reported as allegedly linked to the issue, but no injuries have been confirmed.
Ford responded to early reports by issuing two Technical Service Bulletins (TSBs) in December 2012. Dealers were instructed to seal and undercoat specific areas of the rear floor pan and body seams, replace the left-side air extractor and install rear lift gate drain valves. In July 2012, Ford also released software updates for the air conditioning system to address the problem.
Despite these measures, owners continued to report that the repairs had little or no effect on the presence of exhaust odours. The number of potentially affected vehicles has not been disclosed by either Ford or NHTSA.
Next steps for the investigation
The NHTSA’s investigation is a preliminary step and does not automatically trigger a recall. The agency will assess whether a safety defect exists and decide if further action, including a recall, is warranted. Ford has stated it will cooperate fully with the investigation, as is standard practice.
Owners of affected Explorer models have expressed frustration at the persistence of the issue after attempted repairs. The NHTSA has not provided a timeline for its review. For previous regulatory actions involving Ford SUVs, see US Regulator Investigates Ford Freestyle SUVs for Unintended ‘Lunging’.
