NHTSA Complaint #11702555 — 2015 FORD F-150

Truck started making a loud sound from engine compartment on startup after towing camper 150 miles. The sound started to get louder and started to notice exhaust smells in the cabin. I took the truck into dealer to find out that the exhaust manifolds were warped leaking on both sides of engine due to a stud being broken that holds the manifold in place the tech said it sounds like a diesel. The service advisor at the dealership said that it is a "common problem" on the 3.5L twin turbo engine. The cab of the truck fills with the exhaust fumes to the point where the driver gets headaches unless the windows are open. I asked if there was a recall on this problem and they said NO. The same manifolds was used for years on that motor, since then Ford redesigned the manifolds to use extra studs into the heads that are already there but now want the consumers to pay to install the new design to keep the fumes out of the cab. Looking online it seems to be a problem that the turbos are heating the manifolds to the point that they warp and snap the only stud used on the rear portion of manifolds for owners that tow with the truck (that has a tow package and rated at 12500 capacity) FYI I'm only towing 5000 pounds. My concerns are that the exhaust fumes can overcome the driver an cause them to pass out or become impaired by the carbon dioxide poisoning.