NHTSA Complaint #11043100 — 2015 FORD EXPLORER

MY 2015 FORD EXPLORER LIMITED STARTED HAVING PROBLEMS 2 DAYS AFTER PULLING OUT OF THE DEALER. THEY HAVE NOT STOPPED. UNFORTUNATELY, I WAITED TOO LONG FOR A LEMON LAW CLAIM. MOST IMPORTANT PROBLEM: THE SMELL OF EXHAUST IN MY CABIN UNDER HEAVY ACCELERATION, SINCE DAY 1. IT HAS BEEN IN 10 TIMES SINCE AUGUST 2015. THE EXHAUST HAS BEEN TAKEN APART MULTIPLE TIMES 1."TRANS ROLL RESTRICTOR RUBBER HANGING AGAINST EXHAUST PIPE" WAS FOUND. REPLACED ROLL RESTRICTOR. DID SOMETHING WITH TSB. 2. RETURNED FOR SAME SMELL: REPROGRAM HVAC MODULE, REPLACED LEFT REAR AIR EXTRACTOR, APPLIED SEEM SEALER TO AREAS IN TSB. REPLACED GRILLE AND VALVE ASSEMBLY. 3. TWO MONTHS LATER, SAME THING - REPLACED GRILLE AND VALVE ASY, REPROGRAMMED HVAC MODULE, REPLACED AIR EXTRACTOR 4. ONE MONTH LATER: INSTALLED MUFFLER ASY; RVC CODE FOR TSB 1; REPLACED WHEEL LIP MOLDING,VALVE ASY, DUAL RATE AIR EXTRACTOR STILL HAVE THE SMELL, BUT AM ALWAYS TOLD THEY DON'T SMELL IT. I HAD TWO PEOPLE GET SICK AND VOMIT IN MY TRUCK BECAUSE OF THE FUMES IN STOP AND GO TRAFFIC. ADDITIONAL PROBLEMS: 1. REAR RUNNING LIGHTS DID NOT WORK - TWICE AT DEALER TO GET REPAIRED 2. AIR BAG LIGHT ON CONSTANTLY - WIRE ASSEMBLY - TSB 16 WAS SPLICED 3. AWD OFF & ABS LIGHTS CONSTANTLY ON - COST ME $582 FOR THEM TO TAKE EVERYTHING APART AND CHECK "PIN FIT" AT ALL TERMINALS. AT WHICH POINT THE CODES WENT AWAY. 4. DRIVER-SIDE OUTSIDE DOOR HANDLE JUST BROKE OFF WHEN I WENT TO OPEN THE DOOR - $149 5. WHEN VEHICLE IS PUT IN PARK I GET AN ERROR MESSAGE VEHICLE NOT IN PARK. I NEED A SHIFT MODULE, $395 PLUS TAX AND FEES 6. MULTIPLE OTHER SMALL PROBLEMS. VENTS NOT STAYING OPEN, PLASTIC COVERS COMING OFF EVERYWHERE, SPEAKER REPLACED TWICE MY EXPLORER HAS BEEN IN THE SHOP MORE TIMES THAN I CAN COUNT AND FORD DOES NOT GIVE LOANER CARS. I'VE BEEN WITHOUT A CAR FOR DAYS AT A TIME.