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.
Ford F-150 fuel smell problems
180 of the 38,399 owner complaints about the Ford F-150 describe gas smell in the cabin, most of them for the 2002 model year.
- owner complaints
- 180
- worst model year
- 2002
- typical repair cost reported
- $2,000
- typical mileage
- 89,429
Is there a fix? There are 14 recalls for this area of the car. See below
By model year
Often reported together
Fuel leak 28Check engine light 7Fire or smoke 5Stalling 4Misfire 4Loss of power 4Won't start 2Slipping 2
What owners say
Cruise control kicked on and won't go off. Gas fumes come from the AC unit. When driving the truck started speeding up. Now the truck is parked.
I am reporting a persistent safety issue involving exhaust fumes entering the passenger cabin of my 2018 Ford F-150. The vehicle was purchased January 20, 2025 and has since experienced repeated mechanical failures and extended repair attempts. Despite extensive work completed under warranty - including a transmission rebuild, full engine replacement, alternator/battery/starter replacement, rear main seal repair, transfer case repair, and transmission pan repair - the exhaust odor inside the cabin has never been resolved. The odor is strong enough that passengers have experienced headaches and nausea while the HVAC system is operating. The vehicle has spent well over 150 days in repair facilities since purchase while technicians attempt to diagnose and repair the issue. The dealership currently still has the vehicle and has not been able to identify or fix the cause of the exhaust fumes. This condition raises serious safety concerns regarding possible exhaust or carbon monoxide entering the cabin. I am requesting that this issue be documented and reviewed as a potential safety defect.
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.
Transmission Repairs, Molded Lead Frame Components Due to sudden downshift symptoms from sixth speed, gear to fist speed gear while drive higher speeds and low speeds. $1,421.00 Repairs completed 9/10/2025, at [XXX] , [XXX] , [XXX] . [XXX] , [XXX] , [XXX] , knowingly sold this said vehicle as Certified Pre-OWNED 8/27/2025. Now additional concerns, issues have been discovered with said vehicle Monday, September 22, 2025, AM, 1. Oil burning odor inside the passenger compartment. Vacuum Pump Gasket Failure, allowing oil to drip onto the exhaust manifold hot engine parts, components. Valve Cover Gasket Leaks. Safety consideration, due to symptoms, this vehicle is UNSAFE to operate, drive. Technical bulletins TSB’s were stated as issued from Ford Motor Company Engineering Service Operations, Ford Customer Service Division, Mr. [XXX] , Director, Ford Motor Company, [XXX] , [XXX] . Symptoms include Fuel Dilution PCV System TSB 15-00003, addresses fuel odor inside the passenger cabin on EcoBoost engines, this 3.5 L V6 (DOHC) Turbocharged Twin, PCV Valve Calibrations to reduce the fuel dilution in the engine oil. Oil leaks from the valve cover gaskets and turbo seals especially when accelerating and stopping said vehicle. Creating the oil dripping onto hot engine parts, components, causing the strong burnt oil smell within inside the passenger compartment while driving said vehicle. Intercooler condensation, 2011-2012 EcoBoost 3.5L V6 engine experiences intercooler condensation leading to above symptoms and causing stumbling while driving, operating said vehicle and misfiring, which also creates is accompanied by odors within passenger compartment. Safe Concern, vehicle can cause, catch fire due to oil, fuel leak, seapage into related component areas, while driving, operating. Your serious attention please and the costs asso INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
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
The contact's son-in-law owns a 2019 Ford F-150. The contact stated that while driving at an undisclosed speed, there was an abnormal clicking sound coming from the engine. The contact stated that there was an abnormal exhaust odor entering the cab. There was no warning light illuminated. The contact inspected the vehicle and became aware that the exhaust manifold bolts were fractured. The vehicle was taken to the local dealer, where it was determined that the manifold and bolts needed to be replaced. The vehicle was not repaired due to the cost. The manufacturer was contacted, and a claim was filed with the manufacturer. The contact was referred to the federal safety agency Hotline. The vehicle remained at the residence and had not been driven since. The failure mileage was approximately 116,000.
The contact owns a 2001 Ford F-150. The contact stated that upon entering the vehicle one day, there was an abnormal fuel odor outside the vehicle. The contact’s husband inspected underneath the vehicle and discovered that the fuel tank had detached from the subframe. The contact stated that prior to becoming aware of the failure, the low fuel warning light was occasionally illuminated. The vehicle was not taken to a local dealer. The local dealer was contacted, and the contact was informed that there were no open recalls on the vehicle. The vehicle was not repaired. The manufacturer was notified of the failure. The approximate failure mileage was 93,000.
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?
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.
Related recalls
Fuel system, gasoline: storage: tank assembly: mounting
- What is wrong
- Ford Motor Company (Ford) is recalling certain 2023-2027 F-150 vehicles. The fuel tank may be improperly secured and leak fuel, or detach from the vehicle while driving.
- Risk
- A detached tank can create a road hazard, increasing the risk of a crash. In addition, a fuel leak can cause an engine stall or increase the risk of a fire.
- Remedy
- Dealers will inspect and replace the fuel tank straps, as necessary, free of charge. Owner notification letters were mailed September 21, 2026. Owners may contact Ford customer service at 1‑866‑436‑7332. Ford's number for this recall is 26S69. Vehicle Identification Numbers (VINs) involved in this recall will be searchable on beginning September 14, 2026.
Recall number 26V578000 · Recall details
Fuel system, gasoline: delivery: fuel pump
- What is wrong
- Ford Motor Company (Ford) is recalling certain 2021-2023 Bronco, Explorer, Lincoln Aviator, F-250 SD, F-350 SD, F-450 SD, F-550 SD, 2021-2022 Lincoln Navigator, Mustang, F-150, and 2022 Expedition vehicles. The low-pressure fuel pump may fail, which can result in an engine stall while driving.
- Risk
- An engine stall increases the risk of a crash.
- Remedy
- Dealers will replace the low pressure fuel pump on super duty vehicles and update the powertrain control module (PCM) software on all other affected vehicles, free of charge. Owner notification letters were mailed July 27, 2026. Owners may contact Ford customer service at 1‑866‑436‑7332. Ford's number for this recall is 25S75.
Recall number 25V455000 · Recall details
Fuel system, gasoline: storage
- What is wrong
- Ford Motor Company (Ford) is recalling one 2021 F-150 vehicle. A single vehicle may have been assembled without a fuel tank front attachment resulting in an unsecured fuel tank attachment strap.
- Risk
- An improperly attached fuel tank increases the risk of a fuel leak and potential for fire.
- Remedy
- Dealers will inspect and repair (if necessary) the fuel tank strap bracket, free of charge. Owner notification letters were mailed July 1, 2022. Owners may contact Ford customer service at 1‑866‑436‑7332. Ford's number for this recall is 22S42.
Recall number 22V414000 · Recall details
Fuel system, gasoline: delivery: fuel pump
- What is wrong
- Ford Motor Company (Ford) is recalling certain 2018 Ford Expedition, F-150, and Lincoln Navigator vehicles equipped with 3.5L GTDI V6 engines. These vehicles have high pressure fuel pump assemblies with welds that can fracture, which may cause an oil or fuel leak.
- Risk
- A fuel leak in the presence of an ignition source may increase the risk of a fire.
- Remedy
- Ford will notify owners, and dealers will replace the high pressure fuel pump and associated components, free of charge. The recall began July 17, 2018. Owners may contact Ford customer service at 1‑866‑436‑7332. Ford's number for this recall is 18S17.
Recall number 18V392000 · Recall details
Fuel system, gasoline: storage: tank assembly: mounting
- What is wrong
- Ford is recalling certain 1997 through 2003 model year ford f-150, 2004 model year ford f-150 heritage, 1997 through 1999 model year f-250 less than 8,500 lbs. Gross vehicle weight rating (gvwr), and 2002 and 2003 lincoln blackwood vehicles manufactured from june 20, 1995, through august 4, 2004, originally sold, or currently registered in, connecticut, delaware, illinois, indiana, iowa, kentucky, maine, maryland, massachusetts, michigan, minnesota, missouri, new hampshire, new jersey, new york, ohio, pennsylvania, rhode island, vermont, west virginia, wisconsin, and the district of columbia. Prolonged exposure to road deicing chemicals may cause severe corrosion of the fuel tank straps which secure the tank to the vehicle.
- Risk
- As a result of the corrosion, one or both straps may fail allowing the fuel lines to separate from the tank, or in some cases, causing the tank to contact the ground. Either scenario may result in a fuel leak presenting a fire hazard.
- Remedy
- Ford will notify owners and instruct them to take their vehicles to a ford or lincoln dealer to have the fuel tank straps replaced with straps that have increased corrosion protection. Early in this campaign, if replacement straps are not available, dealers may install a cable support under the strap as an interim repair or a steel reinforcement over the existing strap as a permanent repair. Any repairs will be performed free of charge. The safety recall began on september 16, 2011. Owners may contact ford motor company customer relationship center at 1‑866‑436‑7332. Ford's recall campaign number is 11s21
Recall number 11V385000 · Recall details
Fuel system, gasoline: storage: tank assembly
- What is wrong
- On certain trucks built with 26 gallon fuel tanks, the fuel tank may have a depression at the seam between the top and bottom halves of the tank (not visible from outside the fuel tank). If a depression is large enough, fuel may permeate the fuel tank wall resulting in a fuel odor, or a "service engine soon" indicator light.
- Risk
- If left uncorrected, a fuel leak could eventually develop. A fuel leak in the presence of an ignition source could result in a fire.
- Remedy
- Dealers will replace the fuel tank free of charge. The recall began on june 25, 2007. Owners may contact ford at 1‑866‑436‑7332.
Recall number 07V278000 · Recall details
Fuel system, gasoline: storage: tank assembly: mounting
- What is wrong
- On certain trucks equipped with 4.2l, 4.6l and 5.4l gasoline engines, the fuel tank may have a depression at the seam between the top and bottom halves of the tank. If a depression is large enough, fuel may permeate the fuel tank wall resulting in a fuel odor, illumination, of the "service engine soon" indicator light, or a fuel leak.
- Risk
- Fuel leakage, in the presence of an ignition source, could result in a fire.
- Remedy
- Dealers will replace the fuel tank. The recall began september 17, 2004. Owners should contact ford at 1‑800‑392‑3673.
Recall number 04V443000 · Recall details
Fuel system, gasoline: storage: tank assembly
- What is wrong
- Certain pickup trucks may have a fuel tank with localized depressions in the fuel tank wall at the seam between top and bottom halves of the tank. If a depression is large enough, fuel may permeate the fuel tank wall resulting in a fuel odor, or the "service engine soon" indicator light in the instrument cluster may illuminate.
- Risk
- If left uncorrected, a fuel leak could eventually develop.
- Remedy
- Dealers will replace the fuel tank on these vehicles. Owner notification began on may 6, 2004. Owners should contact ford at 1‑800‑248‑0186.
Recall number 04V200000 · Recall details
Fuel system, gasoline: storage: tank assembly
- What is wrong
- Vehicle description: light duty trucks and cab chassis equipped with gasoline engines and dual fuel tanks. The carbon steel fuel pressure regulator in the fuel system can wear out during the life of the vehicle. If the fuel pressure regulator malfunctions, it can cause high fuel system pressure, which damages the fuel pump check valve. This allows fuel to be transferred from one tank to the other, possibly overfilling the non-operating tank, resulting in fuel overflow past the filler cap.
- Risk
- Fuel leakage in the presence of an ignition source could result in a vehicle fire.
- Remedy
- Dealers will have a stainless steel fuel pressure regulator installed. Owner notification began july 9, 2001. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact ford at 1‑866‑436‑7332. (see previous the federal safety agency recall 93v‑125/ford recall 93s68).
Recall number 00V424000 · Recall details
Fuel system, gasoline: delivery: hoses, lines/piping, and fittings
- What is wrong
- Vehicle description: light duty pickup trucks manufactured at the kansas city or norfolk assembly plants. The front fuel line assembly could have a hole rubbed through in one of two locations. The first location is below the fuel rail connection where the flexible hose is crimped to the steel tube. The bracket that attaches the front fuel line to the transmission could have been bent during assembly. The second location is at the rear steel tube section forward of the rear bracket. During installation the rear steel tubes of the front fuel line assembly could have been bent downward. In vehicles equipped with a manual 4xz4 transfer case shifter, the shifter linkage may contact the steel tubes as it is being shifted between 4h, 4l, 2l and neutral.
- Risk
- This condition could result in fuel leakage. Fuel leakage in the presence of an ignition source could result in a fire.
- Remedy
- Dealers will inspect these lines and replace the front fuel line assembly if necessary. Owner notification began october 27, 2000. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact ford at 1‑800‑392‑3673.
Recall number 00V231000 · Recall details
Questions about the Ford F-150 fuel smell
Which Ford F-150 years have gas smell in the cabin problems?
The model years with the most reports are 2002 (17 complaints), 2016 (14 complaints) and 1997 (12 complaints).
How much does it cost to fix gas smell in the cabin on the Ford F-150?
Owners who mentioned a price put the repair at about $2,000 (median of 20 complaints that include a dollar amount). Costs vary with mileage, warranty and where the work is done.
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