NHTSA Complaint #11633427 — 2022 FORD BRONCO SPORT

Cabin exhaust smell = leaking catalytic converter. 4 months and 5 trips for a diagnosis/solution. Car was smelling like exhaust in the cabin. Improved with air recirculation button ON. Worse in the AM, especially with remote start on cold mornings, and when stopped/parked. Told there was no smell, changed cabin filters / ac deodorizer ($200 out of pocket), “ford doesn’t have any other complaints on exhaust smell in the cabin”, “could not replicate”. After multiple forum searches/my own research, and insisting the catalytic converter was the problem, they agreed to let me leave it overnight for a cold start in the AM. Finally diagnosed with leaking catalytic converter. They replaced it and now the smell is completely gone. There was also a small rattle on acceleration, near the gas pedal, like a tiny rock in a tin can, that I assume was related because it is gone since the replacement.