2020 Ford Explorer: gas smell in the cabin

Filed Apr 15, 2026 · Engine · OK

My vehicle is experiencing manufacturers defect identical to Ford program 21B35, yet Ford tells me my VIN is not covered under this program. Manufacturer defect includes car converter welds breaking, causing exhaust fumes to enter the cabin. This is a serious safety concern.

Filed Dec 18, 2025 · Transmission · IL

The car started hard shifting, bucking like an animal in the middle of driving 70 on the highway, hard to control, hard to stay out of traffic, started to smell like fuel was in the cabin, it took all I had to keep it in my lane and get over to safety without killing myself or someone else, took it to the dealership, they could not look at it for two weeks, took it to a different shop, he found that a wire had been cut and some hoses were zip tied to the frame ( previously only work on this car has been at dealership) he then towed it to the dealership at the two week appointment and they say its burning transmission fluid and hard shifting and needs a new transmission. The warranty expired two days before this occurred so not covered, it is a 2020 , should not have to completely replace a transmission only 74,000 miles on it . I had taken it n three times previously for hard shifting but it was an occasionally occurrence, they could never find any codes to explain so did not look further than what the computer said. That day, it did not throw any codes, until the secondary mechanic took the time to look under the hood, find the cut wire and fix that. Then he had 3 pages of codes. Now I not only have to pay the financed amount on this vehicle but I have to pay an additional 10,000 for a car that did not do its high functioning job and report a problem when i was feeling the problem and probably could have been a warranty fix before the warranty expired if the code appeared the first time, telling the computer to tell the technician to fix it.

Filed Aug 18, 2025 · Transmission · CA

The exhaust leaks constantly and ford can’t seem to fix it. Been multiple times in the shop and all they say is it’s suppose to leak soot and make a fluttery sound. Three documented cases of it at the shop for exhaust leak and I’ve finely gave up because multiple dealerships refuse to acknowledge the issue and state it’s weep holes but weep holes are at connection joints. The smell of exhaust from start up or in tight confined spaces allows the exhaust to creep back into the car if windows are rolled down. Also the sound is embarrassing

Filed Mar 12, 2025 · Engine · OR

The car has 66,311 miles and both catalytic converters are cracked and leaking exhaust into the passenger compartment. The down pipe flex joint on the passenger side is leaking and the one on the driver’s side is deteriorating. Car is currently at the dealership being evaluated. This appears to be a known problem with the 3.0 Ford Explorer in the model years 2020-2022 but no recall has been issued. The problem has been identified by both the dealership and an independent transmission repair shop. There has been no warning lights just strong exhaust smell in passenger compartment when idling at stop signs or lights.

Filed Jul 30, 2024 · Fuel system · 54,000 miles · CA

The contact owns a 2020 Ford Explorer. The contact stated that while driving at various speeds, the contact became aware of an abnormal fuel odor inside the vehicle. There were no warning lights illuminated. The vehicle was inspected by a relative who became aware that one of the fuel hoses was fractured. A local dealer was contacted; however, the vehicle was not repaired due to the cost. The manufacturer was made aware of the failure and referred contact to the federal safety agency Hotline for assistance. The failure mileage was approximately 54,000.

Filed Jun 12, 2024 · Engine · 39,000 miles · FL

The contact owns a 2020 Ford Explorer. The contact stated while driving at approximately 40 MPH, there was an abnormal exhaust odor inside the cabin of the vehicle. The contact stated no warning light was illuminated. The contact stated that the odor was present while driving. The contact had taken the vehicle to a local dealer, where it was diagnosed and determined that the left exhaust flex pipes needed to be replaced. The vehicle was repaired. The contact was advised by the dealer that the manufacturer had issued a Customer Satisfaction Program: 21E11 – Left side Exhaust Flexible Pipe(s) and Left side Catalytic Converter inspection and replacement (Engine and Engine Cooling), however, the vehicle was no longer covered under warranty. The manufacturer was informed of the failure. The failure mileage was approximately 39,000.

Filed May 14, 2024 · Engine · 38,000 miles · NC

The contact owns a 2020 Ford Explorer. The contact stated that while operating the vehicle, exhaust fumes were present inside the cabin of the vehicle and an excessively loud exhaust sound was coming from the exhaust system. The vehicle was taken to the local mechanic to be diagnosed. The contact was informed that the weld on the catalytic converter was cracked. The contact was informed that the catalytic converter needed to be repaired or replaced. The vehicle was not yet repaired. The manufacturer and local dealer were notified of the failure, but no assistance was offered. The failure mileage was 38,000.

Filed Apr 4, 2024 · Engine · 27,000 miles · ID

The contact owns a 2020 Ford Explorer. The contact stated while driving 40 MPH, there were exhaust fumes inside the vehicle. There were no warning lights illuminated. The vehicle was taken to the dealer and a diagnostic was performed. The dealer stated there were 2 cracks in the exhaust system, causing the exhaust to enter the cabin of the vehicle. The dealer also stated that both flex pipes needed to be replaced. The vehicle was repaired. The manufacturer was made aware of the failure. The approximate failure mileage was 27,000.

Filed Mar 22, 2024 · Engine · 24,000 miles · MD

The contact owns a 2020 Ford Explorer. The contact stated that while operating the vehicle, the odor of exhaust fumes was present inside the cabin of the vehicle. The vehicle was taken to the local dealer who diagnosed that the exhaust flex pipe had cracked and needed to be replaced. The vehicle was not yet repaired. Also, while driving at various speeds the vehicle inadvertently shut off. The cause of the failure was not yet determined. The manufacturer was notified of the failure, but no assistance was offered. The failure mileage was 24,000.

Filed Aug 19, 2023 · Engine · LA

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.

Filed Oct 21, 2022 · Engine · 47,500 miles · FL

The contact owns a 2020 Ford Explorer. The contact stated that while driving at an undisclosed speed, there was an abnormally loud sound coming from underneath the vehicle. Additionally, an abnormal exhaust odor was detected while the vehicle was idling. The vehicle was taken to an independent mechanic who diagnosed that the failure was related to Customer Satisfaction Program: 21B35 (Right-Hand Catalytic Converter and Right-Hand and Left-Hand Exhaust Flexible Pipes) however, the VIN was not included. The vehicle was not repaired. The manufacturer was made aware of the failure and advised the contact to file a complaint with the federal safety agency Hotline. The failure mileage was approximately 47,500.

Filed Jan 13, 2022 · Engine · PA

A police officer dropped this SUV off complaining of an exhaust smell coming through the vents in the vehicle. upon opening the hood ,a strong odor off exhaust from the right side of the motor could be smelled .No visible leaks or sounds were noticed. The vehicle remained out of service until our local Ford dealer could service this vehicle.