NHTSA Complaint #10429888 — 2009 FORD FLEX

UPON MODERATE TO HEAVY ACCELERATION THE CABIN FILLS WITH CARBON MONOXIDE (EXHAUST FUMES) POST CATALYTIC CONVERTER. IF CABIN IS NOT QUICKLY VENTILATED BY OPENING ALL WINDOWS THE EYES ARE IRRITATED AND A VERY STRONG ROTTEN EGG SMELL RESULTS INDICATIVE THAT THE EXHAUST IS ENTERING THE CABIN AREA AFTER THE CATALYTIC CONVERTERS. THE VEHICLE HAS BEEN SERVICED BY TWO FORD DEALERSHIPS WHO REPLACED THE CABIN VENT BAFFLES. THIS HOWEVER DID NOT FIX THE PROBLEM. FORD CONCEDES IT IS A PROBLEM THAT STILL EXISTS ON 25% OF ALL FLEX MODELS BUT REFUSES TO MITIGATE THE PROBLEM EVEN THOUGH UNDER WARRANTY. THE DANGER OF THIS AMOUNT OF EXHAUST GASES POSES A HEALTH AND SAFETY ISSUE HOWEVER FORD ENGINEERS HAVE YET TO RESOLVE THE ISSUE AND IT STILL EXISTS ON LATER MODELS.