NHTSA Complaint #11459881 — 2016 FORD ESCAPE

Turbocharger failed, leaking exhaust fumes directly into the car cabin. Turbocharger flange warped on the high heat exhaust side due to two of the three support bolts shearing off. Bolts failed because they were a dissimilar metal to the part they were threaded into, and the chemical process between the dissimilar metals weakened the overall strength of the bolts. Once the bolts sheared off, the flange face warped, allowing exhaust fumes to leak into the cabin. The exhaust fumes into the cabin were quite excessive, especially noticeable while parked, and caused headaches and lightheadedness for the occupants. This is a clear manufacturing defect, as any engineer knows not to mix metals in this fashion, and the result was very dangerous to the occupants.