2021 Ford Explorer: gas smell in the cabin

Filed Nov 17, 2025 · Engine · MD · 1 injury

My vehicle is experiencing exhaust fume issue where the exhaust fumes are entering into the cabin for Explorer and Aviator models (Any model with the 3.0L Ecoobost). Upon inspection by 3rd party mechanic, it can be determined that the problematic catalytic converters that are not the one piece cast was installed on my vehicle from the factory. Speaking to other ST and Interceptor owners, the problem seems widespread to every 2021 model that Ford installed the multipiece welded catalytic converters. Apparently the cast part fairs better and is not subject to cracks. The recall originally covered the left side catalytic converter but the flawed design also affects the right side catalytic converter where many owners are experiencing this issue. This has affected all 3.0L Ecoboost engine vehicles. [XXX] I believe the recall should have extended to cover all 2020 and 2021 model year vehicles. There are forum posts where owners outside the recall have experienced the issue in addition to owners having to repeatedly replace the catalytic converters post warrant as Ford continued to reinstall bad catalytic converters as part of the repair process. I have driven this vehicle for several thousand miles with the issue and did not realize exhaust was leaking until notices of headaches and health issues as CO is odorless, causing CO2 levels to reach 3000+ inside the cabin at stop lights and blows in through the vents if A/C is on. I believe the federal safety agency should investigate this issue further and require Ford to replace both catalytic converters as this issue poses a serious health hazard, especially given the location of the exhaust leak and the commonplace occurrence. I am happy to forward to forums and provide evidence of this occurring. Ford considers lifetime of the vehicle to be ~150K miles and these exhausts do not last close to that, resulting in a massive expense and danger to US consumers. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Filed Jun 12, 2025 · Engine · 89,000 miles · MO

The contact owns a 2021 Ford Explorer. The contact stated that while his wife was driving at an undisclosed speed, the driver heard an abnormal sound coming from the rear of the vehicle. The contact stated that the failure recurred while the vehicle was idle. Additionally, the contact stated that the driver had noticed an abnormal exhaust odor coming from the outside of the vehicle. The vehicle was taken to the dealer, where it was diagnosed that the catalytic converter had fractured at the welds location and needed to be replaced. The vehicle was not repaired due to cost. The vehicle was then taken to an exhaust system center, where it was being diagnosed. The vehicle was not repaired. The contact related the failure to Ford Campaign Number: 21E11. The manufacturer was not made aware of the failure. The failure mileage was approximately 89,000.

Filed Mar 25, 2025 · Engine · WI

We were driving the vehicle when we experienced a sudden loss of power and acceleration. We also noticed odors of gas. We took it to a Ford authorized dealership and they said it was due to antifreeze in the oil from what they said was a leaking water pump. They recommended a new engine due to the difficulty of changing the internal water pump and the fact it leaked antifreeze into the engine oil, possibly damaging the engine itself. This was the explanation for the fault codes, random gas odors, and loss of power. It was explained this was normal when the sensors detect something wrong with the oil in the engine. Estimated cost provided by the dealership was $11,000 to replace the engine.

Filed Dec 3, 2024 · Fuel system · 44,000 miles · TX

The contact owns a 2021 Ford Explorer. The contact stated that after parking the vehicle, there was an abnormal fuel odor inside and outside the vehicle. The vehicle was taken to the local dealer who diagnosed that the fuel hoses had ruptured due to the hoses making contact and rubbing together. The contact was informed that the fuel hoses needed to be replaced. The vehicle was not yet repaired. The manufacturer was notified of the failure but offered no assistance. The contact was informed that the VIN was not included in the federal safety agency Campaign Number: 19V859000 (FUEL SYSTEM, GASOLINE). The contact indicated that the vehicle had experienced the failure listed in the recall. The failure mileage was 44,000.

Filed Feb 14, 2023 · Fuel system · 41,000 miles · IL

The contact owns a 2021 Ford Explorer. The contact stated while driving 10 MPH, there was a strong gasoline odor inside the cabin of the vehicle. Additionally, the contact stated while the vehicle was parked in the garage, there was a strong gasoline odor coming from the vehicle. The contact stated that the gasoline odor was present throughout the entire three-story residence. There was no warning light illuminated. The vehicle was taken to the dealer where it was diagnosed that the fuel line was leaking from a hole. The fuel line was replaced, and the diagnostic fault codes were cleared. The contact stated that upon reviewing photographs of the fuel line, he noticed that an unknown component had been rubbing against the fuel line, which caused the failure; however, the dealer did not inform him of the cause of the failure. The manufacturer was notified of the failure, but no assistance was provided. The failure mileage was approximately 41,000.