NHTSA Complaint #11539510 — 2020 FORD EXPLORER

Faulty exhaust downpipe. Vehicle made loud rattling by catalytic converter, upon investigation the downpipe exhaust hanger rod had broke off due to vibrations in the flex pipe. Ford has an issue with the flex pipe in which it is to weak and will shake the downpipe during idle or acceleration. Ford had issued a factory fix for the downpipe; however, it doesn't fully fix the flex pipe vibration issue. My flex pipe shake so violently that it broke the metal exhaust hanger rod by the catalytic converter. Without the hanger support further shake could result in cracking along the exhaust/catalytic converter. This could result to exhaust fumes being ventilated into the passage side of the car. This could result in carbon monoxide poisoning. As a pilot, they always teach us to check the exhaust for cracks and teach awareness due to the exhaust being near the cabin. Fords fix is to place a hose clamp which doesn't work. Multiple explorer forums have reported this issue. Fords solution to it is to replace it with the same part. Not sure how that will fix the issue if your replacing a defective designed part with another defective design part. I have attached photos of the snapped hanger and hanger location.