NHTSA Complaint #11517547 — 2015 FORD F-150

The exhaust manifold on the drivers side has sheared a bolt on the back of the manifold, and has warped. This is more noticeable when the engine is cold, but is also noticeable after the engine has been off for 10-15 minutes. On acceleration, there is a chirping noise that will go away when the metals have expanded and "sealed" the leak. When cold, exhaust fumes can be smelled in the cabin of the vehicle. This issue appears to be common among the truck variant of the 3.5L EcoBoost V6 engine (11-16 F150, 15-17 Expedition/Navigator, 15+ Transit). There are numerous posts online from many different forums about this exact issue. Ford has even redesigned the manifold to include an additional stud hole, but there is no TSB or FSA from them to replace this on affected vehicles (BL3Z-9430-D, DL3Z-9431-D) This issue was determined through my own inspection of the vehicle. I can bring the vehicle into a shop for an official diagnosis if necessary. There are no warning lights or messages on my vehicle. This initially started around April 5th.