2015 Ford F-150: gas smell in the cabin

Filed Oct 16, 2026 · Engine · 89,000 miles · ID

The contact owns a 2015 Ford F-150. The contact stated that while driving at 35 MPH, the vehicle emitted a loud chirping sound and an exhaust odor entered the cabin. The vehicle was taken to the dealer, where it was diagnosed with fractured exhaust manifold stud bolts and a warped exhaust manifold requiring replacement. The failure mileage was approximately 89,000.

Filed Dec 2, 2025 · Engine · WI

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.

Filed Mar 26, 2025 · Engine · PA

Broken exhaust bolt on passenger manifold. Exhaust leak... Felt as though Carbon monoxide gas was entering cabin portion of truck. Smelling of exhaust in cabin of vehicle. Made wife and kids nauseated and lightheaded. Did research and found out that ford had a poorly designed manifolds and didn't utilize all exhaust bolts. In turn caused the #8 bolt to snap and manifold to warp and release exhaust fumes

Filed Apr 17, 2023 · Engine · NE

The exhaust manifold on the drivers side has sheared a bolt on the back of the manifold, and has warped. This is more noticeable when the engine is cold, but is also noticeable after the engine has been off for 10-15 minutes. On acceleration, there is a chirping noise that will go away when the metals have expanded and "sealed" the leak. When cold, exhaust fumes can be smelled in the cabin of the vehicle. This issue appears to be common among the truck variant of the 3.5L EcoBoost V6 engine (11-16 F150, 15-17 Expedition/Navigator, 15+ Transit). There are numerous posts online from many different forums about this exact issue. Ford has even redesigned the manifold to include an additional stud hole, but there is no TSB or FSA from them to replace this on affected vehicles (BL3Z-9430-D, DL3Z-9431-D) This issue was determined through my own inspection of the vehicle. I can bring the vehicle into a shop for an official diagnosis if necessary. There are no warning lights or messages on my vehicle. This initially started around April 5th.

Filed Mar 6, 2023 · Engine · MA

The exhaust manifolds keep failing on the truck because of a poor design that Ford is aware of with TSB and updated parts it cost $2200 the first time to repair now I am looking at replacing the same exhaust manifold when the manifold fails it let’s exhaust fumes and gases into the cabin of the truck

Filed Oct 1, 2022 · Engine · NE

Exhaust Manifolds warping. This issue is not only very disappointing that Ford hasn't addressed this issue but is a safety concern as well. This allows exhaust fumes to escape not only into the air but potentially inside the cab. This could result in serious lung issues and needs to be addressed. Thank you!

Filed Jan 21, 2020 · Engine · 59,500 miles · OH

Tl* the contact owns a 2015 ford f-150. The contact stated that after driving the vehicle for several hours, there was an abnormal exhaust odor in the vehicle. The contact stated that the failure was more evident in warmer climates after the vehicle was driven for more than an hour and a half. The vehicle was first taken to matthews currie ford located at 130 n tamiami trail, nokomis, fl 34275, (800)248-2378 to be diagnosed. The mechanic was able to pinpoint a pinhole sized leak however, when the vehicle was taken to nick abraham elyria ford located at 1115 e broad st, elyria, oh 44035, (440) 366-3673, the mechanic was unable to pinpoint a location for the possible exhaust leak. The contact was informed that no repairs would be made if the mechanic was unable to duplicate the failure. The vehicle was not repaired. The manufacturer was not contacted or informed of the failure. The approximate failure mileage was 59,500.

Filed Aug 5, 2019 · Fuel system · 24,600 miles · MD

Tl* the contact owns a 2015 ford f-150. When the engine was started, the contact proceeded to load the vehicle and noticed a strong fuel odor. The contact checked underneath the vehicle and found fuel on the ground. The vehicle was towed and the driver of the truck diagnosed that the fuel tank's plastic connector was unprotected, which caused the fuel tank plastic connector to fracture. The manufacturer was not notified. The vehicle was towed to an unknown dealer, but was not diagnosed or repaired. The VIN was not available. The failure mileage was 24,600. *as