Terrible exhaust fumes in the truck cab when using the heat or ac probably due to the extremely common exhaust manifold issues with these trucks. It could kill me and my child
Ford F-250 fuel smell problems
27 of the 4,361 owner complaints about the Ford F-250 describe gas smell in the cabin, most of them for the 2003 model year.
- owner complaints
- 27
- worst model year
- 2003
- typical mileage
- 91,000
Is there a fix? There are 12 recalls for this area of the car. See below
By model year
- 20131
- 20112
- 20081
- 20041
- 20037
- 20011
- 20001
- 19991
- 19974
- 19942
- 19931
- 19912
- 19903
Often reported together
What owners say
The contact owns a 2008 Ford F-250. The contact stated while driving approximately 60 MPH, the cabin began to fill up with diesel exhaust fumes and white smoke. The contact stated that "Drive Vehicle to Clean Exhaust Filter" warning light illuminated. The contact rolled down the window to relieve the cabin of exhaust fumes and smoke. The contact noticed that a rubber boot around the 4WD shift lever inside the vehicle was completely melted, and only a thick plastic ring around the shift lever opening where the rubber boot was attached remained. The contact replaced the rubber boot; however, the failure reoccurred within a week after replacement. The contact had taken the vehicle to a local dealer, where it was diagnosed and determined that the exhaust pipes needed to be replaced and that the repair required the vehicle cabin to be removed. The vehicle had not been repaired. The manufacturer had not been informed of the failure. The failure mileage was approximately 130,000.
I have been trying to get the exhaust manifold bolts replaced by several machine shops and did my own checking on the Ford F-250 Web site and everyone tells me the same thing! Ford knows about the problem but is doing nothing to correct! I have finally found a shop that will fix the broken exhaust manifold blots ! But I would like to know what ford truly knows about this problem . To get it fixed they have to replace all the bolts do to the bolts being so rusted ! Now I only have 121, + miles on my2003 and with the bolts broken it starts admitting gas fumes into the cab . I did check your site and could only find but 1 complaint , so if this is an issue with the exhaust manifold bolts braking and all the ford forums are full of complaints where are they being filed at on your site ? And I do believe it is an issue because I have spoken to 5 different shoppes and 1 ford dealer , they all say the same thing SORRY but it is your problem ! ford knows but will not do anything about it ! I am having mine put in the shop for repairs on the week of 7 Feb 2022 , now that I found someone I could afford! I had quotes from I will not do the work because it is a V10 to $1000.00 per bolt please address this ! It won’t help me but maybe it will hold ford accountable for the product !
When stationary exhaust fumes are drawn into cab of truck by the air handling system. This is an ongoing problem.
Spark plug blowout.when driving on the highway had a sparkplug blow out of the engine.limped the truck home slowly with gas fumes every were.very dangerous. Ford wont admit they have a problem but they do have a fix.your dollars not theres.this is also the second time this has happened to me.
The truck had what sounded like valve tap going on when it was started. I thought nothing of this since truck is a 2003 but this was a change from earlier trip. I proceeded to drive the truck since no warning lights were on and power seemed fine. Going 35-40 MPH about 1 mile from home I heard what sounded like a shotgun going off and the truck began to run badly and I limped it home with windows down because of gas smell. The next day I opened the hood to see what was going on and I found cylinder #2 had blown apart the coil pack and had also ejected the spark plug from the cylinder head. Following that I took removed all other coils and plugs to find that 5 of the 8 were loose and working their way out of the threads. I believe that the only thing that prevented an engine fire was the fact that the spark plug had shorted itself out. This is a serious problem. I have since found that the problem seems to be on many years and models and is due to faulty cylinder heads that were made of aluminum that was to soft. The spark plugs had been replaced once and I checked them after I bought the truck used, I tightened to correct specs with a torque wrench.
#6 spark plug blew out of the head. I had it repaired two days later. Two days after that, the #3 spark plug blew out of the head while I was driving at 25mph. During both incidents gasoline fumes and exhaust filled both the engine compartment and the passenger compartment.
Tl* the contact owns a 1991 ford f-250. After the vehicle was parked, the contact noticed a strong fuel odor from the side of the vehicle. The contact noticed fuel pouring out of the opening of the tank that spilled onto the street and underneath another vehicle. The dealer stated that the fuel check valve in the pump unit was damaged, which caused the fuel to travel from one tank to the other and overflow. The vehicle was not repaired. The manufacturer was not informed of the failure. The approximate failure mileage was 137,000.
This is the fourth time this has happened, the spark plug shoots out of the block and shortly after you can smell gas fumes with is an obvious fire hazard. Not only is it expensive to find a mechanic who can coil the plug back into the block, after reading about it the same incident happens to many owners who have the same truck as I do. Yet, there hasn't been a recall.
Tl* the contact owns a 2011 ford f250 sd. The contact stated that there were exhaust fumes inside the vehicle and the check engine warning light was illuminated. The vehicle was inspected by an authorized dealer and advised the contact that the cause of the failure was an obstructed exhaust gas recirculation cooler cord. The exhaust gas recirculation cooler cord was replaced. The manufacturer was not made aware of the failure. The failure mileage was 9,900. The current mileage was 19,000. ## VIN passed ## 2011 ford super duty ##
Related recalls
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: delivery
- What is wrong
- Ford is recalling 64,754 my 2008 f-250 and f-350 single rear wheel, 4x4, 156 inch wheel base pick up trucks equipped with a two piece drive shaft for failing to conform to the fuel spillage requirements of federal motor vehicle safety standard no. 301, "fuel system integrity." during a 30 MPH frontal impact into a rigid barrier, the fuel tank can move forward and contact a frame cross member, potentially causing damage to the fuel delivery module which can result in fuel spillage.
- Risk
- Fuel spillage, in the presence of an ignition source, could result in a fire.
- Remedy
- Dealers will install a bracket on the affected vehicles free of charge. The recall began on may 23, 2008. Owners may contact ford at 1‑800‑392‑3673.
Recall number 08V191000 · 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
Fuel system, gasoline: storage: tank assembly
- What is wrong
- Vehicle description: pickup trucks equipped with gasoline engines and 8 foot boxes, may not fully satisfy the requirements of fmvss no. 301, "fuel system integrity." in a 30 MPH frontal barrier crash test, a fuel tank vapor recovery valve separated internally. During the subsequent static rollover test, fuel spillage exceeded the specified rate.
- Risk
- Fuel leakage, in the presence of an ignition source, could result in a fire.
- Remedy
- Dealers will install a stop plate assembly on the vehicle frame to prevent recovery valve contact with a frame crossmember during the impact sequence.
Recall number 99V311000 · Recall details
Fuel system, gasoline: storage: tank assembly
- What is wrong
- Vehicle description: gasoline and diesel engine pickup trucks equipped with 8 foot beds, do not fully satisfy the requirements of fmvss no. 301, "fuel system integrity." the fuel tank front strap isolator may not be properly positioned which could result in the strap cutting the tank during a 30 MPH front barrier test, resulting in fuel spillage.
- Risk
- During the subsequent static rollover test, fuel spillage exceeded the specified rate, increasing the risk of a fire.
- Remedy
- Dealers will reposition the front strap isolator.
Recall number 99V219000 · Recall details
Fuel system, gasoline: storage: tank assembly: mounting
- What is wrong
- Vehicle description: pickup trucks equipped with 6" beds manufactured from january 5, 1998 through june 4, 1999, do not not fully satisfy the post crash test static rollover requirements of fmvss no. 301, "fuel system integrity." contact between the fuel tank and a fuel tank locator bracket during a front barrier impact test resulted in a cut in the tank, resulting in fuel leakage.
- Risk
- Fuel leakage in the presence of an ignition source could result in a fire.
- Remedy
- Dealers will replace the fuel tank locator bracket with a similar bracket whose design has been revised to incorporate more rounded surfaces where contact with the tank occurs.
Recall number 99V093002 · Recall details
Fuel system, gasoline: storage: tank assembly
- What is wrong
- Vehicle description: gasoline and diesel engine pickup trucks equipped with 6" and 8" beds manufactured from january 5, 1998 through march 21, 1999, do not not fully satisfy the post crash test static rollover requirements of fmvss no. 301, "fuel system integrity." six attachment bolts (m12 bolts) may have been damaged during the 30 MPH front barrier test allowing the bolts to shift or become detached, resulting in fuel spillage.
- Risk
- Fuel leakage in the presence of an ignition source could result in a fire.
- Remedy
- Dealers will augment the box-to-chassis attachment by installing box-to-chassis retaining cables.
Recall number 99V093001 · Recall details
Fuel system, gasoline: fuel injection system
- What is wrong
- Vehicle description: light duty pickup trucks. The fuel pressure regulator o-ring may have been damaged when the fuel pressure regulator was installed in the engine fuel rail. If the o-ring is damaged, fuel vapor or leakage could occur.
- Risk
- If an ignition source is present, a fire could result.
- Remedy
- Dealers will replace the fuel pressure regulator.
Recall number 98V194000 · Recall details
Fuel system, gasoline: delivery: hoses, lines/piping, and fittings
- What is wrong
- The steel fuel return tubes that connect the frame fuel return lines with the engine fuel rail can contact the pinch weld flange connecting the dash panel to the floor pan. Continued contact leads to abrasion of the steel fuel return tube and eventually results in a fuel leak.
- Risk
- Abrasion of the steel tube wall that eventually causes a fuel leak may result in a fire, if a source of ignition is present.
- Remedy
- Ford dealers will replace the fuel return tubes with flexible stainless steel braided/teflon tubes. Dealers will also inspect the fuel supply tubes.
Recall number 94V040000 · Recall details
Questions about the Ford F-250 fuel smell
Which Ford F-250 years have gas smell in the cabin problems?
The model years with the most reports are 2003 (7 complaints), 1997 (4 complaints) and 1990 (3 complaints).
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