2016 Ford F-150: gas smell in the cabin

Filed Jul 15, 2024 · Engine · TN

Exhaust manifold broken studs(bolds) causing exhaust fumes in cab. Carbon monoxide and also loss of performance. This is an ongoing issue with the 3.5 L equal boost motors. Pre 2017. The 2017 motor and further have been redesigned. Why aren’t they doing a recall on pre 2017?

Filed Feb 15, 2024 · Engine · TX

The bolts on the exhaust manifold cannot withstand the torque and heat generated from the engine and turbos. The bolts snap and cause sagging and warping of the manifolds, which allow for unfiltered exhaust fumes to release into the engine bay and sequentialy into the main cabin. This not only causes carbon filled exhaust enter the environment, but it also exposes to passengers as well as any children in the cabin to carbon dioxide and carbon monoxide. This is a known design flaw by the engineers at Ford, and they have released a second generation of the manifold including an additional bolt hole. There have also been aftermarket parts created for this with more bolt holes to match the amount of holes that are available in the engine. Being a this is a known design flaw and increases environmental and personal risk, should be formally acknowledged by Ford and a recall should be administered at the cost of the company.

Filed Jan 13, 2024 · Fuel system · FL

When fueling the Ford F 150, it will not shut off almost all fuel handles and as a result gasoline spews out a couple feet past the fuel pump handle as well as spilling fuel all over the side of the truck. This poses a fire hazard as well as slipping and carcinogen issue. Also, the paint and tires are subjected to deterioration and the vehicle smells of fuel for some time afterwards. I can never completely fill the vehicle without putting my ear up to the truck fill tube. No matter how far back I jump, I always get fuel on my feet, shoes and clothing. I haven't had fuel get in my eyes yet, but it is just a matter of time. Maybe a fuel station has already blown up. I'm sure that won't bee long if it has not already happened.

Filed Apr 12, 2023 · Engine · NC

2016 Ford F-150 3.5L LH Exhaust Manifold Failure. Resulting in the potential release of exhaust fumes into the passenger cab. Recently experienced severe flutter noise and loud exhaust noise from the Left Hand Side of my engine. After diagnosing the flutter noise upon start up and acceleration was coming from the LH turbo charger "Waste Gate" the turbo was removed and prior to replacement it was found that the two aft exhaust manifold studs were also sheared off. After several attempts to remove the two studs failed, and some internet investigation (including this the federal safety agency website) it was decided it was best to remove and replace the complete exhaust manifold and studs. Fortunately FORD found it in their favor to increase the number of rear port studs from 2 to 3. After installation of the new exhaust manifold, gaskets, studs and turbo charger for a total cost of approximately $3,000 the truck runs exceptionally well once again.

Filed Dec 28, 2022 · Engine · TX

Driving home form work I started getting an exhaust smell, kept driving and once I came to a complete stop at a light my entire cabin filled with exhaust white/blue smoke. I pulled over to check it out, opened the hood and the exhaust was coming from the back of the engine. A wrecker driver pulled up behind my truck, got out with his fire extinguisher for safety. He is the one who told me to look into the manifolds warping or the bolts breaking. The wrecker driver said the smoke in the cabin is carbon monoxide and not to transport and small children. The rest of the day, I had severe headaches. I took it to a shop and they have told me I will need new manifolds and gaskets and potentially a few other gaskets when removing the turbos. They also said this could have damaged my turbos and may lead to other exhaust issues, vehicle performance issues and definitely will not let my vehicle pass the emissions test in Texas. This appears to be a Ford design flaw and hopefully a nation wide recall can be implemented. The shop also recommended not to drive it because the cabin filled with smoke or rather a cabin full of carbon monoxide. This could cost me over $5000.00 to replace all part. Something needs to be done by FORD to fix this issue. I will have to find a way to pay for this as having a vehicle to and from work is necessary. My daily round trip to and from work is 80 miles.

Filed Sep 28, 2022 · Engine · PA

Exhaust manifold failure on an F-150 with a 3.5L Ecoboost engine with only 65000 miles. Exhaust fumes enter the truck cab when the engine is running and the truck is stationary. One exhaust manifold was replaced under an emissions system warranty. The other is also leaking at about 70000 miles and Ford doesn’t think they need to replace it as a manufacturing design issue.

Filed May 26, 2022 · OR

The rearmost exhaust manifold bolts have broken due to poor design. This will significantly increase the risk of exhaust fumes collecting in the engine and passenger compartments

Filed Feb 17, 2022 · Fuel system · 85,000 miles · FL

The contact owns a 2016 Ford F-150. The contact stated that the vehicle was parked and idling, when the contact returned to turn off the vehicle, there was an abnormal gasoline odor surrounding the vehicle. The contact stated no warning light was illuminated. The contact had not taken the vehicle to the local dealer. The contact had an independent mechanic diagnose the vehicle and was advised that a gasoline feeding tube under the driver’s side seat located on the frame was too short for its connection to the fuel pump and to the engine. The independent mechanic informed the contact that the connection was under pressure and was leaking gasoline and could detach from the connector and spray gasoline onto the engine. The contact called a local dealer and provided the dealer with the part number for the hose (FL34-9J278-AE). The vehicle was not repaired. The manufacturer had not been informed of the failure. The failure mileage was approximately 85,000.

Filed Jul 21, 2021 · Fuel system · 80,000 miles · TN

The contact owns a 2016 Ford F-150. The contact stated while driving 35 mph, the pressurized fuel line fractured causing an abnormal fuel odor inside the vehicle. The contact exited the vehicle and became aware of fuel leaking from the fuel line. The contact stated that there was no warning light illuminated. The vehicle was taken to a local dealer where it was diagnosed with the fuel line needing to be replaced. The vehicle was not repaired. The manufacturer had been informed of the failure but offered no assistance. The failure mileage was approximately 80,000.

Filed Dec 12, 2020 · Engine · 75,000 miles · NY

My 2016 ford f-150, at around 68,000 miles, began to experienced power loss and a loud whistle or whining sound during acceleration, coming from the front left and right side of the engine. During acceleration, a high-pitched whine occurs and increases when revving the engine. Truck power loss was noticeable and boost declined, dropping to less than 25%. Exhaust fumes were noticeable from inside the cab of the truck. Depaul ford of albany, ny misdiagnosed it as a bad turbo with a stuck open wastegate and so we replaced the passenger side turbo, which did not fix the problem. The truck was brought to a highly recommended mechanic 'technician', matt, at miller's corners garage in albany, ny. He discovered the bolts and studs that hold the manifolds in place were severely rusted and the manifold was warped with significant air leak and blow by. There was a large black sooty streak on the manifold side where the turbo hooks up, where the blow-by was occurring. At a cost of $1100 the passenger side manifold, hardware and related components were replaced. The driver side manifold is not available from ford until late december and still requires replacement. The vehicle has been well taken care of and is driven in upstate new york. It is rarely used for towing. It's absurd to think that a truck with such low mileage would have such a severe and expensive issue, significantly decreasing engine power, reducing the life of the engine and bringing fumes into the cab. This should be a recall issue.

Filed Oct 29, 2020 · Engine · 102,000 miles · MD

My 2016 ford f150 recently started whistling at the 2500rpm point from the front end of the my truck. I took it to the dealership expecting a vacuum hose issue and was told both exhaust manifolds had warped and broke off some of the mounting bolts. I was a bit shocked since the vehicle has 102,000 miles on it and it's not been abused in anyway. Unfortunately, the factory warranty runs out at 100,000 miles and on the hook for the cost of this $1600+ (so far) repair. After doing a little research on the internet it did not take me long to discover this is a very well known problem with the 3.5l ecoboost engine. There were a multitude of websites and youtube videos addressing this known problem with folks quite upset that an official recall has not been issued yet with a proper fix/replacement and reimburse the owners who have already paid for the fix. Seems like it's not a matter of if it's going to happen to your truck...but when. Very disappointing, especially when you hear how many known issues have already been reported. Exhaust fumes leaking from the engine and possibly into the cab...should take a high priority to resolve. Let's go ford...make it right! Thank you.

Filed Oct 10, 2019 · Engine, Fuel system · 56,968 miles · TX

While using my vehicle under normal conditions the check engine light came on so I had vehicle checked at autozone and o'reily's which showed 2 different codes and took it to machaik dealership. Turns out I had to have both cylinder heads replace, crankshaft bolt replaced as well as a few other items. I was told it was an issue that ford was aware of and didn't notify me of it when I bout the vehicle. They covered the cost due to the vehicle being under warranty which was about $5,000. $ months later I got my vehicle back and about 30 miles of driving 55mph it started blowing a thick cloud of white smoke with some grey smoke. I take the vehicle home and let it sit for 28 days before I have to use it and after about 23 miles it started smoking again. I take it to the same dealership again and I told them about the smoking issue, rough idle and the exhaust smells like gas which is not normal. I showed them a video of the issue which contains my mileage at the time and my license plate which clearly shows my vehicle so they cannot say it wasn't my vehicle. Waiting for the results of their findings and plan to update the complaint. I will not upload the video at this time due to it containing my license plate, don't know how to upload it from phone and I don't know how to edit that out. If it is necessary to update this complaint I will upload the video as proof as well as work order from previous and current work.my mileage will not be 100% accurate but it will be within 400 miles plus or minus