I just took my 03 6.0 into the shop for an oil change and to have them check the exhaust smell I had in the cab. Turns out that the Y pipe was cracked and they are replacing it. But during the replacement process, they stripped the bolts when tyring to remove the turbo. Now its been 4 working days that they have had my truck and they still aren't sure if they will be done today. Guess we will see what we have when I get it back, if I ever do.

 

Boy T_ the cracked "Y" pipe is a very common fix for those with this exhaust in cab issue. Have these dealers throughly checked this out with engine at normal operating temp? Does smell in cab cease when you put vent controls on re-circulate?

Sorry if this is redundant.

 

They did a visual, they said no carbon was spotted and they say that the "Y" pipe TSB doesn't apply to '05's. They are being told by Ford that if they remove or replace anything and it is tested and shows no problem they have to eat the repair so you can see how a dealer might hesitate. As for the re-circulate, it sort of stops it until you roll down a window at a stop. That is a very temporary work around because IMO it is just as bad to keep breathing the same air for hours at a time.

*Update*
Spoke with the service mgr and he is trying to get in touch with the area rep to see what we have to do to start a buy back. May have to go to the DSB.

 

I agree that recirulate is a very temp. work around. Just trying to find you some temp relief. Sounds like Ford is hog tying dealers with diagnostic opportunities, though I can understand it to some extent.

IMO Ford should address every opportunity to keep an '05 out of DSB this soon in the model year.

Good luck with Ford and your return to very, very, cold country.

 

I take that to mean they did a design change, could be very small, and figured it is fixed....any takers on my theory

 

If it's true and they are not just blowing smoke (pun intended) then yepper, I would agree with design change.

However, it could be that TSB's on previous model builds are not offically blessed with use on new model builds. Could still be a problem and Ford has not yet ammended the previous TSB's to include '05. Probably won't until they see enough complaints.

If no TSB...no pay for no fix. Man, could turn into an ugly problem.

Either one is a guess on my part.

 

Shortly after I bought my 04 F-250 CC Lariat PSD, I smelled what I thought was exhaust fumes entering the cab through the vents. Today, my agency (county government hazmat) got in some excellent new Gas detectors that can check for Carbon Monoxide, Hydrogen Sulfide, LEL, (any flamable gas) and Oxygen. I put the probe into my vent and started up the Diesel engine. Now that my rig has 600 miles on it, the fume smell is bairly there anymore, but I checked it at Idle, moving slowly, at cruising speed and the detector never moved off zero.
To confirm the detector was working correctly, I held the probe back at the exhaust pipe outlet and the CO (carbon monoxide) and H2S jumped way up and alarms went off, proving that the meter was working. I put the probe under the hood, near the turbo and both exhaust manifolds + Y-pipe and it read zero. I was able to confirm that my truck doesn't have any exhaust leaks, even though I thought that it did due to the fumes I smelled before it had 500 miles on it.
The gas detector I used was a Biosystems PhD5
http://www.smglink.com/biosystems/de...phd5/phd5.html
This thing cost about 5 grand I think, so it is unlikely that car dealers would have one, but I imagine that they could use their smog testing wand near the vents to see if your truck is truly leaking exhaust through the vents. I noticed that my fumes were vastly reduced after I got the 500 miles on it and then ran it hard enough to get the turbo cooking hot, so that might have burned off the last of the cosmoline, varnish or whatever was causing the stink. Happy with my truck now.

 

Guys- Ive never thought to post this before, but...

If you will notice on these trucks, there is no exhaust gasket where the manifolds bolt to the heads, similar to old style headers. With the manifolds being cast iron (and the heads) and the fairly significant pre-turbo exhaust backpressure, the manifolds will generally not seal well against the head until the truck is driven for some time, enough to build up some corrosion and expand with heat to sufficiently seal them.

ALOT of the trucks right off the lot have the exhaust smell. Mine had it; unless the y-pipes are cracked, it will eventually go away. Some take longer to seal than others.

 

I appreciate all of your input!!!

I spoke with the service mgr yesterday and he told me that after a conversation with the area rep (who talked to the field service rep) there is nothing that Ford will do at this time being that the condition is NORMAL. I was told to call customer service and file for DSB. You notice that they do not say it is not happening, they just keep saying it is normal.

When I get back to MT in about 5 days (snow willing) I will investigate finding a sniffer to use on this thing. I think if I go to our local fire dept their haz mat team should have one. Being that we are in a relatively small town they tend to be real good about helping out.

Now that Ford is forcing my hand I have to decide weather to outright sue them (cost to me is $100) where I will have legal reps who are just as expert at this as Ford or, try the DSB thing. It will be interesting to see how this will be handled since it started in NC but I will now be in MT. What realllllly gets me is the apperant lack of caring from Ford on who they hurt. I can't help but wonder how they would feel if it was their family who is getting gassed.

Well, hope to be back on the boards by the 10th or so.....See Ya then

 

I spoke with the service mgr yesterday and he told me that after a conversation with the area rep (who talked to the field service rep) there is nothing that Ford will do at this time being that the condition is NORMAL. I was told to call customer service and file for DSB. You notice that they do not say it is not happening, they just keep saying it is normal.

If the Ford Area Rep recommended that you file a DSB it seems to me that he / they are trying to help. Often times a process is slow, but there is a process. It would be virtually impossible in any business to say OK...we recognise the condition and at this point in time it is normal but, go pick out a new truck.

I can't help but wonder how they would feel if it was their family who is getting gassed.


Believe me, I do not mean to be flipant here but, we all have a responsibilty to provide a safe environment for our family and others...If you truely feel that your family's immediate and / or long term health is at risk...park the truck.

In regards the DSB or filing suit: Probably will be a challenge since you are moving to a distant stae and different region of Ford. IMO i would try the DSB first and see what happens but, I really wouldn't know thw best course of action for your special situation.

Again, safe travels during your move and please keep us informed.

 

Good luck and safe driving back to MT.

 

If each person having this problem would open a complaint on the NHTSA (national highway traffic saftey administration) web page, Ford may eventually have to do a recall. I did a search and there is not one complaint against a 2004 F250 super duty for this problem.


try this link http://www-odi.nhtsa.dot.gov/cars/problems/complain/
to search for other complaints, recalls etc or to enter your complaint.

If you consider this a safety issue it is the least you could do.

Hope this helps,
Dan

 

If you consider this a safety issue it is the least you could do.
I couldn't agree more. If you you are truely concerned. Take action, make something happen. Strength in numbers.

 

I did call NHTSA and they logged the complaint and then sent me a long form to fill out. In the hustle to move I have not filled it out yet but will as soon as we are settled again. I agree with y'all, if everyone doesn't go to NHTSA then there is no watchdog to keep Ford honest and they can do as they please. I am not saying that NHTSA will jump right on it but if they get enough reports they will have to investigate. I am guessing that if they get multiple reports of this exhaust problem they will take notice quickly since it is a safety issue.

 

Be careful out there on your big trip home t_