Smell

[TouchOfEvil]

This is a very common complaint for Ford. They have this problem on just about every vehicle they make after doing research on it. There is a 50+page thread on another board for this very subject.
Ford has TPS out for certain vehicles but it doesn't actually work for most people and if the ride in question was built after XX/XX date it was performed during the build process and just did not work.
There have been many people try to get buy backs from this issue and Ford turns them down.
One fellow on the other board said he sued using the lemon law and won. No idea if that is true or not though.
From most of what i have seen is the smell enters the cabin via the recirculate on the ac system.
Everyone gets it after a hard accel above 70mph. This is a very common problem that Ford to date has not come out with a real fix for it.

[BiGMaC]

This is a very common complaint for Ford. They have this problem on just about every vehicle they make after doing research on it. There is a 50+page thread on another board for this very subject.
Ford has TPS out for certain vehicles but it doesn't actually work for most people and if the ride in question was built after XX/XX date it was performed during the build process and just did not work.
There have been many people try to get buy backs from this issue and Ford turns them down.
One fellow on the other board said he sued using the lemon law and won. No idea if that is true or not though.
From most of what i have seen is the smell enters the cabin via the recirculate on the ac system.
Everyone gets it after a hard accel above 70mph. This is a very common problem that Ford to date has not come out with a real fix for it.

The "lemon law" in AZ is pretty rigid... mostly just takes documentation of 3 unsuccessful attempts to correct the problem.

[Vortex69]

TouchOfEvil, thanks, do you have a link to that info?

[TouchOfEvil]

TouchOfEvil, thanks, do you have a link to that info?

Yep, sending now.

[IHeartGroceries]

Very interesting. Knew I wasn't crazy.

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[BiGMaC]

OK, so I drove the car pretty hard as an experiment with high and low speed accelerations and steady 90ish mph... no smell in the cabin.   When I got home I garaged it and shut the door.... and outside the car I smelled it... kinda like a freshly paved road.  It wasn't strong, but definitely there.

[Vortex69]

TouchOfEvil, thanks, do you have a link to that info?

Yep, sending now.

Thanks for that link. Way bigger problem than just me.

[Frozen Taurus]

OK, so I drove the car pretty hard as an experiment with high and low speed accelerations and steady 90ish mph... no smell in the cabin.   When I got home I garaged it and shut the door.... and outside the car I smelled it... kinda like a freshly paved road.  It wasn't strong, but definitely there.

Could that just be deposits being burned off the cats? Most cars get that after a spirited driving session if they haven't been driven really hard lately.

[BiGMaC]

True enough!

[TouchOfEvil]

OK, so I drove the car pretty hard as an experiment with high and low speed accelerations and steady 90ish mph... no smell in the cabin.   When I got home I garaged it and shut the door.... and outside the car I smelled it... kinda like a freshly paved road.  It wasn't strong, but definitely there.

Not every vehicle gets the issue but a large number do. Also for me if i'm running with the air off i never get a smell. But if i have the air on it gets in the cabin. It's the worse with ac on and recirc on at the same time.
Personally it's not a big deal because i don't go WOT over 70mph too often so i rarely have the issue anyway.
For others though it seems they get a much stronger ratio of exhaust vs fresh air. Some have reported headaches and so fourth. I guess i'm lucky mine is there but not too terrible.

[SHOdded]

Time to get a charcoal cabin filter & up the change frequency!

[IHeartGroceries]

I did sift through a rather lengthy thread on an Explorer forum about this issue. Seems pretty common on their end.
I see the TSB for this was issued for the Flex, though? Ford describes it in their TSB verbiage as a sulfur smell.
This is pretty weird.
It hasn't happened to me in several days. But, like already mentioned, I don't accelerate heavily beyond 70 MPH too often.

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[Vortex69]

Just an update.

I've run it pretty hard a number of times since I started this post and had no smell as a result, however, recently it has been happening a few times under normal driving. Today, and during a thirty minute drive, my eye's started to burn. It was at that time that I faintly noticed that smell again. Had to drop a window.... Can you imagine how sweet fresh air is after you've been slowly subjected to those noxious gasses?? It now appears that instead of getting a huge blast of those gasses, I am now being slow roasted.

Anyway, looks like I'm headed back to the dealer for a second time.

[IHeartGroceries]

Fascinating. Looking forward to what your dealer comes up with.

I haven't driven mine in a week, so I haven't really been able to test it. Hoping that crap doesn't start seeping in randomly like that! That's horrendous. 

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[BiGMaC]

Good luck... Hopefully the dealer can get it fixed quickly for you! ...

Hopefully it will do the thing for them.... My luck is Not good in that category... Seems I can't ever duplcate problems for the mechanics.