Exhaust Odor in the Vehicle – 2009-2014 Ford Flex

EXHAUST – SULFUR ODOR AFTER HARD ACCELERATION

 

FORD: 2009-2014 Flex

 

2009-2014 Flex vehicles may exhibit an exhaust odor in the vehicle with the auxiliary climate control system on.

This may be more pronounced after hard acceleration or driving in hilly conditions.

Customers may indicate the odor smells like sulfur.

 

SERVICE PROCEDURE

  1. Remove the rear bumper cover.
  1. Inspect the attachment points on the bumper cover. Does foam surround the attachment points? (Figure 1)
    1. Yes – proceed to Step 3.
    1. No – install foam around the missing attachment point locations. Proceed to Step 3.

install foamFigure 1

 

  1. Replace the left side upper / rear air extractor. (Figure 2)

left side upper / rear air extractor Figure 2

 

  1. Is the vehicle a 2012 – 2014 Flex?
    1. Yes – proceed to Step 5.
    1. No – replace both lower / forward air extractors. Proceed to Step 5. (Figure 3)

     

lower / forward air extractorFigure 3

 

  1. Remove the liftgate release switch moulding.
  1. Install foam from the Rotunda Squeak and Rattle Repair Kit (164-R4901) around the liftgate release switch moulding opening on the liftgate. (Figure 4)

liftgate release switch moulding opening Figure 4

 

  1. Install the liftgate release switch moulding.
  1. Install foam from the Rotunda Squeak and Rattle Repair Kit (164-R4901) around the four (4) tail lamp assembly attachment holes. Cut pieces large enough to fully cover the attachment point. (Figure 5)

tail lamp assembly attachment holes Figure 5

 

  1. Open the liftgate and install a new drain valve in each of the three (3) drain holes. (Figure 6)

drain valve Figure 6

 

  1. Raise the vehicle on hoist.
  1. Lower and support the rear section of the exhaust system.
  1. Clean the areas on the underside of the vehicle where seam sealer will be applied. (Figures 7-9)

areas on the underside of the vehicle where seam sealer will be applied Figure 7

 

areas on the underside of the vehicle where seam sealer will be applied Figure 8

 

areas on the underside of the vehicle where seam sealer will be applied Figure 9

 

  1. Cover the exhaust system and auxiliary climate control drain.
  1. Apply a generous amount of Motorcraft Seam Sealer to the rear horizontal sheet metal lap joints on the left and right sides of the vehicle, and the rear sheet metal overlap flange across the rear of the vehicle. (Figures 7-9)
  1. Spray a generous amount of 3M Rubberized Undercoating around auxiliary the air conditioning lines and seam sealer areas. (Figure 10)

auxiliary the air conditioning lines Figure 10

 

  1. Install the rear exhaust system.
  1. Install the rear bumper cover.

 

Obtain Parts Locally
Part Number Part Name
08883 Exhaust Odor in the Vehicle - 2009-2014 Ford Flex » small light 3M Rubberized Undercoating
164-R4901 Foam – Rotunda Squeak And Rattle Repair Kit

 

PART NUMBER PART NAME
AL2Z-61280B62-A Exhaust Odor in the Vehicle - 2009-2014 Ford Flex » small light Grille – Air Inlet (Forward/Lower) (2 Req)
DA8Z-78280B62-A Grille – Air Inlet (Rear/Upper)
4M8Z-54280B62-A Exhaust Odor in the Vehicle - 2009-2014 Ford Flex » small light Valve Assembly Auto Drain (3 Req)
TA-2 Exhaust Odor in the Vehicle - 2009-2014 Ford Flex » small light Motorcraft Seam Sealer

 

Leave a Comment

Share to...