Body/Exhaust - Exhaust Sulfur Odor After Hard Acceleration
TSB 13-4-1904/25/13
EXHAUST - SULFUR ODOR AFTER HARD ACCELERATION
FORD:
2009-2013 Flex
ISSUE
Some 2009-2013 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.
ACTION
Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Remove the rear bumper cover. Refer to Workshop Manual (WSM), Section 501-19.
2. Inspect the mounting points on the bumper cover. Does foam surround the attachment points? (Figure 1)
a. Yes - proceed to Step 3.
b. No - install foam around missing attachment point locations. Proceed to Step 3.
3. Replace the left side upper/rear air extractor. (Figure 2)
4. Is the vehicle a 2012 or 2013 Flex?
a. Yes - proceed to Step 5.
b. No - replace both lower/forward air extractors. Proceed to Step 5. (Figure 3)
5. Remove the liftgate release switch moulding. Refer to WSM, Section 501-14.
6. Install foam from the Rotunda Squeak and Rattle Repair Kit (164-R4901) around the liftgate release switch moulding opening on the liftgate. (Figure 4)
7. Install the liftgate release switch moulding. Refer to WSM, Section 501-14.
8. 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)
9. Open the liftgate and install a new drain valve in each of the three (3) drain holes. (Figure 6)
10. Raise vehicle on hoist. Refer to WSM, Section 100-02.
11. Lower and support rear section of the exhaust system.
12. Clean areas on underside of vehicle where seam sealer will be applied. (Figures 7-9)
13. Cover exhaust system and auxiliary climate control drain.
14. Apply generous amount of Motorcraft(R) Seam Sealer to rear horizontal sheet metal lap joints on left and right sides of the vehicle, and the rear sheet metal overlap flange across the rear of the vehicle. (Figures 7-9)
15. Spray generous amount of 3M(TM) Rubberized Undercoating around auxiliary air conditioning lines and seam sealer areas. (Figure 10)
16. Install the rear exhaust system.
17. Install rear bumper cover. Refer to WSM, Section 501-19.
Parts Block and Obtain Parts Locally
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage Warranty/ESP coverage limits/policies/prior approvals are not altered by a TSB. Warranty/ESP coverage limits are determined by the identified causal part and verified using the OASIS part coverage tool.
OPERATION DESCRIPTION TIME
130419A 2009-2013 Flex: Seal Body 2.0 Hrs.
Includes Time To Replace
Air Extractors Install
Liftgate Drain Valves (Do
Not Use With Any Other
Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
78280B62 68
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