NHTSA Complaint #11064858 — 2016 FORD EXPLORER

FROM THE DAY I TOOK DELIVERY OF MY 2016 FORD EXPLORER SPORT, THERE WAS A PROMINENT SMELL IN THE CABIN THAT APPEARED UNDER MODERATE ACCELERATION. I INITIALLY BELIEVED IT TO BE CAUSED BY THE "BREAKING IN" OF A NEW ENGINE. HOWEVER, THE PROBLEM PERSISTED. PASSENGERS WOULD CONTINUALLY ASK ME ABOUT THE AWFUL "ROTTEN EGG" SMELL IN MY EXPLORER. I WAS GETTING HEADACHES AND FEELING NAUSEOUS AT TIMES WHILE DRIVING MY EXPLORER. AFTER RESEARCHING THE ISSUE ON THE INTERNET, I FOUND COUNTLESS REPORTS OF OTHERS HAVING THE SAME EXPERIENCE WITH THEIR EXPLORERS. I TOOK MY VEHICLE TO AUTO NATION FORD IN SCOTTSDALE, AZ AND THE SERVICE ADVISOR TOLD ME THEY'VE HAD SEVERAL FOLKS WITH THE SAME ISSUE AND THAT FORD HAD ISSUED A SERVICE BULLETIN ON HOW TO RESOLVE THE PROBLEM. I WAS TOLD THAT THERE WAS A DESIGN FLAW LEADING TO THE EXHAUST FUMES RE-ENTERING THE VEHICLE THROUGH THE VENTILATION SYSTEM. THE ADVISOR INDICATED THEY WOULD NEED THE CAR FOR AT LEAST A WEEK TO RE-SEAL THE SYSTEM TO MINIMIZE THE PROBLEM. AFTER HAVING MY VEHICLE FOR SEVERAL WEEKS, I RECEIVED IT BACK AND THE ISSUE WAS NOT RESOLVED. I RETURNED THE CAR TO FORD AND THEY ARRANGED FOR ME TO HAVE LOANER EXPLORER WHILE THEY WORKED ON MINE. IT HAD THE SAME EXACT ISSUE. MY EXPLORER WAS AT THE DEALER FOR WELL OVER A MONTH AND I WAS TOLD THAT THEY WERE WAITING FOR FORD TO ENGINEER AND MANUFACTURE THE PARTS NEEDED TO FULLY RESOLVE THE EXHAUST LEAKS. AFTER FINALLY GETTING THE CAR BACK, THE ISSUE INITIALLY SEEMED TO IMPROVE, BUT QUICKLY RETURNED. THE DEALER HAS STATED THEY HAVE DONE ALL THEY CAN AND THAT NO OTHER FIX EXISTS. THIS IS COMPLETELY UNACCEPTABLE AND UNSAFE. I HAVE A WIFE AND 3 CHILDREN AND I DO NOT FEEL COMFORTABLE DRIVING WITH THEM IN THE VEHICLE BEYOND VERY SHORT TRIPS. WE'VE EVEN GONE SO FAR AS TO RENT VEHICLES FOR FAMILY ROAD TRIPS DUE TO THE ISSUES WITH OUR EXPLORER.