NHTSA Complaint #11498062 — 2008 FORD F-250

The contact owns a 2008 Ford F-250. The contact stated while driving approximately 60 MPH, the cabin began to fill up with diesel exhaust fumes and white smoke. The contact stated that "Drive Vehicle to Clean Exhaust Filter" warning light illuminated. The contact rolled down the window to relieve the cabin of exhaust fumes and smoke. The contact noticed that a rubber boot around the 4WD shift lever inside the vehicle was completely melted, and only a thick plastic ring around the shift lever opening where the rubber boot was attached remained. The contact replaced the rubber boot; however, the failure reoccurred within a week after replacement. The contact had taken the vehicle to a local dealer, where it was diagnosed and determined that the exhaust pipes needed to be replaced and that the repair required the vehicle cabin to be removed. The vehicle had not been repaired. The manufacturer had not been informed of the failure. The failure mileage was approximately 130,000.