2011-2015 Ford Explorer there is a "design flaw" in which the internal cabin air vents are sucking in exhaust and carbon monoxide. Ford has issued a fix (tsb 14-0130) but not a recall and there is a class action lawsuit. For me it is happening on acceleration and going up steep grades and there is a sulfur/mechanical burning smell that wafts in. The kids and I, as well as anyone else in the car for long durations, have been getting migraines, dizzy and just flat out sick. I drive for work and the dizziness and migraines has become so frequent, as well as mixing up words when I'm speaking, that I was beginning to think something is seriously wrong with me. I passed out and wrecked it when I had only 20,000 miles on it and I kept saying "I don't understand what happened, I just passed out". I had gone up the grade on 101, where the fumes become extremely potent, exited, and had just got on to the ranch road and was going slow and I was (for the most part) un-injured and no one was with me. I have had it in 5 times for the smell but it wasn't until this last time that they told me what was really going on. Ford wouldn't pay for the fix even though I have a Ford premium 100K mile warranty because their warranty excludes "design flaws" but fortunately henry curtis Ford picked up the tab and I had to pay the $100 deductible. While the problem is not happening as frequently, it still happens in certain conditions. Ford is refusing to give me a new car. This is a very dangerous "design flaw", which means it's in every Explorer out there, including the ones the law enforcement officials drive. Every one needs to know and Ford needs to do a recall before someone dies...updated 09/15/15 updated 12/05/2017

- Cloverdale, CA, USA

Exhaust fumes are coming in the cab. Strong smell when accelerating fast. My eyes burn and water everytime I drive it. My allergies have been off charts since we purchased it in May 2015. I took it to Ford thinking I have bumper to bumper and 46000 miles left on my warranty so I thought they would solve it's problem. They call me at work and tell me it's not covered under warranty. They tell me it will cost me $700 to fix. I feel like that's on Ford to fix.

- Florence, SC, USA

Radiator hose breached, decompressing radiator. Radiator hose was rubbed open by nearby metal compressor line running perpendicular. Hole was 1" by 1/2". radiator immediately emptied, engine overheated and shuddered. Repair made by Ford dealership only replaced hose and flushed coolant. Ford did not remedy situation where metal compressor line is adjacent and sometimes in contact with radiator hose. I have photo and video proving the ac line rubbed the hose open.

- Baton Rouge, LA, USA

At the3200 mileage I experince brake issues rotary had to be replaced.on the first week of July 2015 additional brake work had to be redone.on july10th 2015 while driving the ac unit went out completly while I was driving on a long extended trip barely made it home no air wierd screehin noise. Scheduled to go back to repair7-14-15. I purchase the vehicle July 2014.the vehicle has 36000. Very unhappy at this point thinking about returning the vehicle and starting over with some other vehicle

- Alvaton, KY, USA

The front edge of the hood has bubbling paint, dealer tried to have Ford cover the repair but Ford denied the repair. Dealership instructed me to call Ford customer service and file a complaint. Ford customer service suggested I file a complaint here with NHTSA.

- Biloxi, MS, USA

Figured out that the constant annoying flapping noise during cross winds while driving at highway speeds that seemed to be coming from the windshield trim or lower door post was actually coming from a loose panel fastener or shield clip on the inner fender splash shield/skirt. There are several of these fasteners and one was loose enough to allow the shield to vibrate. Once that was resecured it hasn't made the noise since.

- Champaign, IL, USA

Burnt oil smell during acceleration or long trips. This is easily repeatable and happens every time.

- Rock Hill, SC, USA

Exhaust fumes in cabin when accelerated.

- Manns Choice, PA, USA

When accelerating, exhaust/gas fumes emitted inside the vehicle through the vent system. Fumes are more profound in the rear, inside vehicle. When vent/climate system is off, no fumes. Seems to be more profound when ac is operating, nevertheless the fumes accumulate to the rear. Started noticing on 11/8/2014 and has worsened each day since. Dealer appointment made for 11/12/2014.

- Centreville, VA, USA

Hear a thunk when chassis under certain stress. Dealership reports it is likely body supports that need to be replaced.

- Washington, DC, USA

When hard accelaration up to 4K RPM exhaust smell or bad odor (something like burnt) comes in from cabin..I brought my car twice at Ford service and they do tsb but still no improvement.

- Washington, DC, USA

When accelerating a stong exhaust smell is present in the vehicle cabin. This is most pronounced during a long acceleration I.e. when entering a highway. Following a period of acceleration we need to open the windows to purge the exhaust from the cabin. This is regardless of the heating/cooling system being on or off, or if the recirculation feature is enabled. The dealership implemented a technical service bulletin for this condition and it had no improvement.

- Ballston Spa, NY, USA

I just bought a 2013 Ford Explorer last week and I am having an issue with burnt oil smell getting inside the cabin even with A/C in recirculation mode. It is such a disappointment to pay over 40K for a brand new SUV and been dealing with such an issue. I have a newborn and I am afraid to take it with me in the Explorer because I guess it is harmful for anybody. First time I bought a Ford and I am not happy about my decision to switch brands. I took to the dealership and need to go back on Monday to do a system update but I don't think updating the software it's going to solve the problem. I hope someone from Ford can read this and pay attention to us because it's not healthy to be driving inhaling harmful fumes.

- Miramar, FL, USA