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Problems with 2015 Ford Explorer FUEL/PROPULSION SYSTEM

On average, the 2015 Ford Explorer starts to “feel” problems with the FUEL/PROPULSION SYSTEM and its various aspects after 26 809 miles.

Recently reported FUEL/PROPULSION SYSTEM problems on 2015 Ford Explorer

The fuel gauge on the instrument panel is reading that the fuel tank is almost full, however while driving the low fuel warning sensor came on and we nearly ran out of fuel. the gauge was still reading almost full. we barely made it to a gas station. after putting in a full tank of gas, the fuel gauge was showing a completely full tank. since then, the gauge is always showing almost completely full and will go down only to almost full, not quite as low as 3/4 full tank, even if you have driven over 300 miles. now we have to re-set the trip odometer every time we get gas, so we can calculate approximately how many miles we have driven since the fuel gauge only goes down slightly below full. this occurred around 50,000 miles.

On 6/6/19 vehicle lost engine throttle power when "wrench" light indicator appeared on dashboard while driving on interstate (at least 65mph). wrench noted terrain management system error. engine did not shut off. vibrated very badly when coming to stop. happened again on 6/12 on city street driving approx 35mph. both times stopped vehicle, turned off, and restarted and operated normally. ford dealerships cannot determine problem because there computer systems cannot see error code(s) in diagnostics.. additionally, ford motor company will not respond until "error code" identified by ford service dealership. read online and youtube exact issues but not discussion on resolution(s). see url address for example of issue that occurred with our vehicle: https://www.youtube.com/watch?v=asrdplp4_qe&t=1s. very dangerous to lose power on highway and little control of vehicle. believe this is a systemic issue with ford explorers

Having a feeling of nausea when driving exolorer. yesterday and today we have been running the ac due to hotter temps. after letting car idle for 5-10 minutes while using remote start i start to feel light headed after about 20 minutes of driving. after feeling fine all day. seems to be only when the car uses ac. today i was in the drive thru for my son while idling when i started to feel light headed. noticed the recirculation mode turns itself on after i turned it off. this issue is quite concerning. was slated to have recall fix done at capitol ford but advisor said it wasnt attached to the vin so they didnt do it.

Had the recall done for (fsa 17n03) after the service was done, we have noticed when passing on the freeway or going up hill, hot air blows out the vents then a heavy odor of exhaust. my vehicle also uses e85, so we have ruled out maybe a car in front of us. when using e85 we get a strong smell of alcohol type. we have been to the dealership for the smell, each time they want the windows done or have the a/c on. i tell them we don't drive with it on all the time or have the windows down on the freeway. every 4-6 months more stories in the news have been coming up with concerns about exhaust smells in the explorer and now ford is redesigned the vehicle. this should be looked at more and maybe with third party engineer.

There is a terrible exhaust smell that comes into the interior cabin. the smell is even worse upon extended hard acceleration. in addition, there is bubbling in my hood due to faulty hoods being produced on ford explorers. ford has acknowledged both issues - as there is a tsb. ford's "fix" tsb-16016 is not a fix at all. it merely is a bandage for the problem as my family still smells exhaust in the vehicle. my 3 year old son is inhaling this toxic smell.

When i accelerate my vehicle you can smell tge exhaust fumes and i instantly can't breathe, get a headache, nauseated, and after a few minutes i get very sleepy. i have to roll my window down and stick my head out to be able to breathe. it doesn't do it every time but in a 3 hour trip, it happens at least 4 times depending on how much accelerating is happening. if my ac unit is on high then it will automatically go to barely blowing and as i let off the acclerator then it will eventually cycle back to high even though it is on high. it is making me very sick because i'm in my car so much. i have taken to ford repeatedly, two different dealerships, and they can't get it fixed. sometimes to get the ac to go back to normal, i have to stop somewhere and turn the car off and back on. this has been happening to me since a few months after i bought the car in feb 2017. my doctor says the only way to correct problem is to get rid of the car but i don't think it needs to be on the road at all. it'll just make someone else sick too.i started noticing the smell in late april 2017 and it just got stronger and i started taking in to ford when it started getting really bad. the vehicle had 30000 + miles when i bought it.

'takata recal' when my car has been sitting in the driveway for a full day without being driven or started. the following day you go to start the car. it starts no problem, once your in reverse the battery light will come on and as soon as you put it in drive i lose all power and function to steer. if i hit the gas petal it will regain power. the light will disappear only if i hit ok. this happens every time without fail. i also smell carbon dioxide or gas fumes from time to time

Loss of power: while driving my 2015 ford explorer xlt with 3.5l v-6 engine on the highway (10/04/18), the wrench light came on and the car started to shudder and lose speed. pushing down on the accelerator had no affect and the car rapidly decelerated. the engine was running very rough with heavy vibration. this was a terrifying and nearly fatal experience as faster moving traffic started passing me on both sides as i tried to move off the highway. i was able to move the car to the side of the highway and limped off the nearest exit. once off the exit i shut the car off and sat for 20 minutes while i re-gained my composure and called my husband. when he arrived he started the explorer and the wrench light was cleared. my husband drive the car home using only back roads while i followed in his car. we called our local ford dealer and scheduled an appointment. we started researching this issue and found this to be a well known problem with the throttle body on ford's v6 engines which are used on multiple suv's, crossovers and sedans. the research i've seen shows this issue has affected more than 10,000 owners. however, it's not clear if the throttle body is faulty due to a manufacturing or design defect. it's also not clear if replacing the throttle body is a permanent fix. i'm terrified to drive the car on the highway and since this happened we've only used it for shorter trips around town. the ford dealer checked the car today (10/08/18) but since the wrench light was cleared they found nothing wrong. i pleaded with the service advisor to no avail. we've been a ford family for more than 15 years but this fault and even worse the ford service advisor's response is completely unacceptable. this is a serious and dangerous problem and only a matter of time before someone and their family are killed. please investigate and force ford to issue a recall.

Exhaust fumes in car while driving

When at idle, either in park or drive, the engine rpms will fluctuate and go down to a point where the engineer stalls or almost stalls.

During acceleration into interstate there is a "burnt match" type smell in the interior of the vehicle. once speed levels out the smell disappears. i first noticed this about a month ago but i purchased the vehicle used and this was only the second or third time to have it on the interstate since i purchased it.

We began to smell exhaust fumes in the cabin of our vehicle. it got stronger the longer the vehicle was running, and especially when idling at a stop light or similar. it began to cause headaches while driving and we had to drive with windows down no matter the temperature or speed. because of the known recall, we took it to the dealer where we bought the vehicle (malloy ford in winchester, va) to repair. they claimed to have fixed the issue but it still persists so now we will have to take it back. i am not sure an actual fix exists.

This particular car was in recall for carbon monoxide, about two months after possibly fixed from a dealer, strong smell coming from cabin left me with a head ache, stiff noise, i'm really worried this might cost me a fortune, i called dealer they asked to bring it they informed me they will charge me $138 for diagnosing and who knows how much from there.

While driving on the highway an error message appeared on my dash, stating the "check fuel fill inlet " and engine light on. had it repaired 9/28/17, fuel tank filler pipe and canister purge solenoid. on 10/25/17 back in the repair shop for same error message. they replaced the solenoid assy and valve assy. now, once again, i have the same error (11/2/17). goes back in the garage to repair on 11/8/17. we'll see what happens.

10aug2017 - when getting in my car after work it was extremely hot. my car had been parked in the parking lot all day without any shade - so the temperature inside the car was soaring. i turned the air conditioning on to full blast to keep from sweating and left the parking lot. while driving the 7 miles from my office to the palm bay ford dealership i opened the sunroof in hopes that the car would cool down quicker. immediately i began feeling light headed. my head began spinning and i started feeling sick to my stomach. in only a few short minutes i started losing vision in my right eye. i never smelled anything through the ventilation system so i opened the window to try and get more air thinking it would help calm me. it made it even worse. i was terrified - i couldn't see to pull over but wasn't sure if i should keep driving. i could only make out the car in front of me - it was rush hour traffic with bumper to bumper cars. i thought if i pulled over it would take longer for someone to get to me in a parking lot than if i continued driving - i was about 3 miles from the dealership. by the time i pulled in to the dealership it was all i could not to throw up. after being at the dealership for 30 minutes i started feeling better. we spoke to the service rep, rose, and she documented the incident in the service record. we talked about the news reports regarding the issues plaguing the explorers. she checked the online service reports for my car and she said it showed green (no recalls or tsbs). i was shocked and couldn't believe my car had not been noted as needing the exhaust replaced after all the reported issues with the 2015 explorer. she said it would be a week before the car was fixed so we left in my husband's truck. this would be the second time i've had the car into the shop for exhaust leaks/issues

I have been experiencing problems with the exhaust on my 2015 ford explorer. ever since i bought the car there's a strong exhaust smell in the cab of the car when you accelerate enough to make the car downshift to pick up speed. we took the car into the dealership shortly after buying the car and it seemed to be ok. when taking the car on vacation in aug 2017 to the mountains we once again began smelling the exhaust fumes again. as the main driver, i have been experiencing terrible headaches when driving the car - fine before i get in, headache within minutes, and then fine after being out of the vehicle for about 30 minutes or more. we took the car to a different dealership who kept it for a week stating they installed a completely new exhaust system from the catalytic converter to the back of the vehicle (as described in the tsb). on the way to the dealership in aug 2017 i experienced a partial blackout on the way to the dealership. it was a very hot day, i was driving in heavy city traffic going from light to light, i had the air blasting in my face, i opened the sun roof and immediately started to feel as i was being drugged. extremely dizzy, sick to my stomach, and began losing vision in my right eye. thank goodness the dealership was within 7 miles - but i barely made it without passing out. i ended up in the emergency the following day for extreme headaches and grogginess. now we are again experiencing very strong exhaust fumes when the car downshifts. this is the same issue reported by the sheriff deputies as my incident is very similar to when the deputy blacked out at the wheel and crashed this summer. it doesn't seem ford knows how to fix the problem and they are not acknowledging this is a 'consumer' problem. not just a problem with deputy vehicles.

Exhaust fumes fill cabin under hard acceleration. it has happened many times over the past few years, we purchased car new in ~ may 2015. typically we can limit by accelerating slower than desired, which can be unsafe when entering the highway. after hard acceleration has ended and you maintain steady speed the fumes no longer seem to enter the cabin. fumes can be very strong and rolling down windows is the only way to clear. it seems to mostly happen with rear air conditioning in turned on, but not sure. i put todays date below, but this happens often. i have read online and spoken to dealers in the past and no fix seems to be available so we have done are best to avoid with slow acceleration, but we can not be certain that no fumes are entering car. both my wife and i seem to get more head aches than in the past and this could be the cause.

When the throttle is depressed fully during passing or increasing speed there is a odor inside the cabin of vehicle. it happens every time the throttle is fully depressed.

7/25/2017 driving on highway at 55 mph, passed a vehicle accelerating to approximately 70 mph. within seconds of slowing back to 55 mph passenger cabin filled with fumes (smells like burning hair) opened all windows but breathing very difficult, had to pull off road and exit vehicle until clear. air conditioner was not set on recirculate at the time. this has been a recurring problem and dealer supposedly "fixed" in june 2016. however, this incident was the first time i had to get out of the vehicle. problem seems to occur more often when air conditioner on or set to recirculate, but does occur when a/c not in use. developed a headache shortly after incident.

Exhaust smell enters cabin of vehicle after hard acceleration.

Carbon monoxide like leak into the cabin ford did not fix when we went to the dealership

Tl* the contact owns a 2015 ford explorer. while the vehicle was stationary, it would not start when prompted. the vehicle was towed to mike reichenbach ford in florence, south carolina where a diagnostic test was performed. the dealer determined that the wires within the fuel pump needed to be repaired. the vehicle was repaired, but the failure recurred. the vehicle was towed to duval ford in jacksonville, florida where the fuel pump was replaced. the manufacturer was not made aware of the issue. the failure mileage was 40,000.

Strong burning/exhaust smell when the car accelerates.

I was driving home from work (doing about 45mph with the heat on) and instantly noticed what smelled like natural gas. i rolled my windows down to see if it was outside and it wasn't. i then turned my heat off and the smell lightened. when i got home i just thought maybe it was a fluke. the next day me and my daughter 12yrs old got in the explorer to go shopping. not 10 minutes into our drive (doing 25 mph with the heat on) my daughter frantically says "i smell gas." i turned around went home. i sat in the vehicle to run a diagnostics report and started feeling slightly light headed. so i got out of the vehicle and told my husband. then i began to have a headache out of nowhere. i then contacted a ford dealer (because our vehicle is under warranty with ford) and as i explained what was going on and i mentioned the articles i read about these vehicles the person on the phone had no response other than when they had their next open appointment. so i am taking my vehicle in next week. the next day i started my vehicle without the heat on and the smell was minimal in the vehicle but when i turned the vehicle off and got out i smelled a very strong gas like smell coming from the front of my vehicle!

There is a gas/propane smell inside of my vehicle which requires the occupants to roll down the windows because of safety concerns. the smell is more prevalent when accelerating and using the air conditioning system. there is a strong exhaust/gas smell present in the vehicle causing sick conditions of all passengers.

Exhaust odor, carbon monoxide present in cabin. check engine light.

Exhaust odor enters the vehicle when accelerating. the fumes seem to be getting worse. also the left front door panel is warped and coming apart. ford has not fixed either problem. service department blows these complaints off in hoping i don't keep calling.

Tl* the contact owns a 2015 ford explorer. the contact stated that a fuel odor emitted from the vehicle when the heater was activated the vehicle was taken to the dealer, but the failure was unable to be diagnosed. the vehicle was not repaired. the manufacturer was made aware of the failure. the failure mileage was 19,000. updated 02/03/17*lj *cn

I smell gasoline inside the cabin of my vehicle and it has made me sick on several occassions.

Intense exhaust odor, especially when accelerating. windows must be rolled down to be able to breathe.

Tl* the contact owns a 2015 ford explorer. while driving 30 mph, a fuel odor emitted from the air vents in the vehicle. the failure recurred on numerous occasions. the vehicle was not diagnosed or repaired. the manufacturer was not notified of the failure. the failure mileage was 18,900.

After heavy acceleration, the cabin has a strong foul sulfur odor that is unbearable. we have had it in to a ford dealership to have both tsb's performed - the second took 5 days! - and it still has not changed. disgusting smell. this happens when we accelerate as on to the highway or to pass in challenging situations. i only have to press the gas pedal about half way down for 4-5 seconds and the smell is overwhelming. activating the turbo chargers for any length of time brings this smell into the cabin. then all of the windows have to go down to clear the smell. my mother can't take this anymore and my wife complains of headaches. this has been an ongoing problem for a year and a half.

When my 2015 ford explorer is under heavy acceleration such as towing or passsing, i can smell a very strong odor of sulpher or convertor fumes in the cabin. it is worse with the fresh air vent and is less with the recirculation. the rear a/c is off and i have 4400 miles on the vehicle. i called my local ford dealer and they have no past complaints of this nature and do not know what it may be. i also had a problem when i was making the high acceleration to duplicate the problem and noticed the steering wheel jerking under torque. i drive front wheel drive police vehicles for a living and never had this happen where you better be hanging on with both hands.

Takata recall - i frequently come close to blacking out while driving the vehicle. on a number of occasions, i have almost crashed the vehicle while driving on the highway. i work in a congested downtown area and sit in stand still traffic for close to 30 minutes twice a day, 5 days a week. i have been to a specialist trying to figure out why i am having episodes of what i thought were "extreme sleepiness". it never occurred to me that the sudden onset of tiredness could be linked to the air in my vehicle, however, now that i am aware of the situation, my symptoms make perfect sense. i am also having frequent headaches and difficulty concentrating and focusing while working. i am the cfo of a real estate company and i have noticed my ability to focus has clearly diminished. the concentration level and work ethic that brought me to my position is being compromised and despite healthy changes to my diet and exercise i cannot maintain the same level of productivity i once had. i would like the interior of my vehicle tested for carbon monoxide because i am certain that it exists and i would like to understand the level of poisonous gas that i have been exposed to.

3.5l ecoboost, 24k miles. upon attempted acceleration, engine does not produce full power. engine lags significantly then surges in both rpm and acceleration. issues has persisted for approximately 3k miles. issue occurs during all environmental conditions. check engine light has not come on. no codes have been found. vehicle has been examined by hudson ford in wisconsin. no resolution provided, issue continues to exhibit itself.

I have been smelling gas inside the cabin of my explorer and it has made me sick on several occassions it was so strong. it is strong when parked and in motion.

Burning plastic / exhaust smell inside the cab any time when accelerating

Since we have had our car 2016 you can always smell a gas like odor type fumes. if the car is driven for a long period of time you get a headache and dizzy. the ford dealership said that they have no issues with carbon monoxide in the fumes. we would like this looked into further as it is a concern. at first, we thought maybe you can just smell it when the car is first warming up, maybe its the heated seats trying to rule everything out. unfortunately, i think we are now use to the smell which is also so bad by ignoring a issue.

We have taken the explorer into dealership a few times for the sulphur smell and was told there was nothing to fix this. now according to the news reports there is a legitimate problem on ford behalf. yes we smell the sulphur when driving the vehicle any distance on the road. we want ford to correct this issue. i have been diagnosed with asthma which i am concerned about my health as well.

Update to nhtsa complaint #10914850 vehicle still in service since 9/26/16. total days at dealer for service due to exhaust fumes / chemical smell in passenger compartment: 26 as of 10/16/16. have been told ford's engineering rep (during ford's "final repair attempt" under lemon law) also smelled fumes in cabin under wot and when engine under load. was told that it could not be carbon monoxide in cabin making me dizzy and sick feeling because "catalytic converter changes carbon monoxide to carbon dioxide, which is why dealer uses co2 meter not co meter". was informed that regional engineer instructed dealer to repeat tsb 14-0130 even though they were then telling me that the smell is from "mildew on the a/c evaporator core", which contradicts their performing the tsb to seal the vehicle from exhaust fumes a second time (performed previously without effect in 10/2015). have been told many different "reasons" for the fumes in cabin, none of which make much sense. mildew does not smell like sulfur or exhaust fumes. to make things worse, i was told that i "do not drive enough miles" during my trips to "dry out the evaporator core" so i am told my driving habits, not ford's design flaws allowing exhaust into cabin, are the reason for the fumes. service manager has been diligent and professional and is a genuinely nice person, though ford is trying to serve up a "red herring" by trying to divert attention to the a/c system rather than admit to exhaust fumes in passenger cabin. ford replaced the evap core which resulted in nearly no a/c upon being told vehicle ready for pick-up on 10/15/16, so it is still in service..now to repair what they broke during "final repair attempt". to consumer, appears ford has propped open fresh air vents regardless of "recirculate" button light, resulting in warm a/c. ford should re-purchase this hazardous vehicle. *tr

Exhaust fumes are entering the passenger cabin of the vehicle while driving. the exhaust is most noticeable during acceleration at highway speeds. i have taken the explorer to the dealer twice where it is still at since oct 5th, today is nov 4th. the ford dealer has performed a tsb to correct the known issue of exhaust entering the passenger cabin. this fix did not correct the problem or lessen it to any degree. using an altair 4x gas monitor inside the vehicle i observed carbon monoxide levels up to 13ppm while driving the vehicle.

On august 22, 2015 i stopped at a shell station near bonham, texas. after refueling i was unable to remove the fuel nozzle from my vehicle. i moved it around, pushed, and pulled on the nozzle to no avail.the vehicle was obviously stationary at this time. after about fifteen minutes and with the help of other people i was unable to get the nozzle out of my vehicle. i told the gas station attendant who was able to push and pull the nozzle enough to get it dislodged from my vehicle. i took the vehicle to the dealer i bought it from auto nation frisco, texas. my vehicle had less than five thousand miles on it at the time of the incident. the dealer refused to replace the capless fuel system component saying it was not broke it was a gas station issue- faulty fuel nozzle?? i spoke to the service manager who refused to replace the component. i wrote a letter to the gm of the dealership as well as the vp of customer service for auto nation explaining the problem and asking to be contacted. as of this writing i have had no response. i filled a complaint with ford motor co. case# 7943196. on 10-8-2015 i was advised that the case was closed. i was never able to talk to them so i left a voice mail and sent a e-mail asking to be contacted. as of this writing i have had no response. i was told by the dealer after the incident that there was a bulletin explaining what nozzles to avoid. seems like good information to have prior to an incident not after!! i believe this to be a real problem and do not feel comfortable using my vehicle until the component is replaced. having to pull, push, and pry to get a fuel nozzle out of your vehicle sure seems like a obvious safety issue. the car dealer and ford motor co. says its not their problem. the gas station attendant said it was a ford problem. consumer stuck in the middle!!

We would get extreme headaches and nausea while driving this vehicle. as soon as we would get out for a period of time all symptoms would go away. we took it back to the dealer several times and it was in the shop longer then we actually had the car and the ford dealership never believed us about the problem.

A follow up on a co problem, that happened on 7/7/15. dealer took the explorer in on the co issue along with ford knowing of it. gave us a rental for a week, and came up with no co levels after a week. went to the dealership to take a ride with the service manager, exhaust was present but he said it was a hot engine smell. no levels where found but symptoms in my body of co where indicated while the service manager was in the vehicle. left the vehicle for the day and was told by ford the service manager found nothing wrong and to come get the vehicle. upon the ride home my co detector indicated levels at 534ppm. with the windows down and the sun roof open at 70mph. along the way i stopped in the local hospital, waited an hour in a half for blood work then walked out. had to get back to work. only 15 minutes back home the levels went up to 871ppm. calling the dealership and ford in the am to get this problem solved asap before some dies. 2015 with only 4,500 miles. ford has known of this problem since 2011. updated 12/05/17*cn

Tl* the contact owns a 2015 ford explorer. while driving approximately 30 mph, a chemical smell emitted from the exhaust into the vehicle. the vehicle was taken to a dealer, who advised that the smell was normal. due to the smell, the contact suffered serious headaches. the manufacturer was notified of the failure and advised the contact to take the vehicle to the dealer for further diagnostic testing. the failure was not repaired. the failure mileage was 1,000.

During and after acceleration at any speed there is a very strong sulphur smell in the cabin of the vehicle. it appears to enter from the rear of the vehicle and it must be exhausted by opening the windows every single time. the fumes contain co2 and are very dangerous to all within the vehicle. all passengers complain of a light headache and nausea.

I loose power while driving. happens all the time. it is very noticeable whe car shift into 3rd gear. my rpm's go from 4000 to below 3000 ( normal acceleration). when i give it a lot of gas i start to smell the turbos burning. probably cause by the fact the etanol gas is not compatible with this twin turbo set up. not to mention the transmission leaks as well as the bottom side of the throttle body. i love ford (american made). but as an american i feel that they felled me. breaks my heart. anyone know where to buy a good chevy from.

During acceleration (getting on highway, passing, etc.) the cab fills with exhaust smell. we immediately have to roll the windows down to get the smell out of the vehicle. frequent passengers and driver with asthma. we have taken explorer to dealer several times but only left it twice as they said they only had 2 technical bulletin's from ford on suggested fixes. still smells. during a google search we found this has been going on since 2011. had we have known we would not have bought this ford explorer.

We bought a 2015 ford explorer in april of 2015. one week after we had the truck we were noticing a nasty rotten egg smell every time we would drive it. we went back to the dealership to have them check it. the service manager drove the truck and said that it was the new smell burning off the exhaust. here we are 2 years later and we are still smelling the same nasty smell. we don't drive very far in the truck because we live very close to everything. so we took the vehicle on a long out of state trip and could not stay awake and had severe headaches. at one point on the trip we thought our 18 year old cat had died because we could not wake her up. now i am finding out that the carbon monoxide fumes could be leaking into the cabin of the vehicle which would explain the symptoms we were all having. i now find out that there have been several tsb issued regarding these same problems. i am so frustrated!

Tl* the contact owns a 2015 ford explorer. while driving at approximately 55 mph, the vehicle began leaking exhaust fumes from the cabin. the contact stated that this was a recurring failure. the vehicle was taken to the dealer for diagnostic testing. the technician stated that the failure was a design issue. the vehicle was repaired. the manufacturer was notified of the failure. the approximate failure mileage was 850. ma 10/19/2015 *cn

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