Symptom Chart: Symptom Chart - Exhaust System

WARNING: This page is about a different variant/trim than selected.

Diagnostics in this article assume a certain skill level and knowledge of Ford-specific diagnostic practices. For information regarding Ford-specific diagnostic practices, REFER to: Diagnostic Methods .

Verify the customer concern. Inspect the components of the exhaust system for obvious signs of damage or other mechanical concerns using the following chart.

Visual Inspection Chart - Mechanical

Mechanical
Exhaust pipe pinched or crushed Damaged catalytic converter Dirty engine air cleaner Damaged DPF Loose or damaged sensors or sensor mountings Damaged tail pipe Clogged passages in tail pipe Damaged muffler Broken or damaged exhaust hanger brackets Loose or damaged heat shields

Verify the exhaust system is installed correctly, with clamps correctly located and tightened to specifications. If the fault is not visually evident, determine the symptom. GO to Symptom Chart below.

Symptom Chart

Condition	Possible Sources	Actions
Loss of power - vehicle performance complaint	Exhaust pipe pinched or crushed Damaged catalytic converter Full/loaded DPF Clogged catalyst or DPF Loose obstruction in exhaust Restricted exhaust (possible frozen condensate in muffler)	INSPECT the exhaust system. REPAIR or INSTALL new components as necessary. If the concern is still present, REFER to the Engine Controls - Symptom Charts (Diesel) .
Loss of power - vehicle performance complaint	Restricted exhaust (possible frozen condensate in muffler)	CHECK drain holes for foreign material. PARK the vehicle inside to thaw. TEST the vehicle for normal operation. If the concern is still present, REFER to the Engine Controls - Symptom Charts (Diesel) .
Burning smell - usually occurs at idle, with possible traces of smoke	Foreign material caught in exhaust system Missing heat shields Fluid leak on exhaust	INSPECT the exhaust system for foreign material or missing heat shields. REPAIR or INSTALL new components as necessary.
Odor - described as a sulfur or rotten egg smell	Catalytic converter	At times, a slight sulfur smell is normal for catalytic converters. The cause is the sulfur content in the gasoline being used. ADVISE the customer no repair is required.
Odor - described as a sulfur or rotten egg smell	Rich fuel conditions Misfire conditions Excessive sulfur content in fuel	REFER to the Engine Controls - Symptom Charts (Diesel) .
Visible rust on surface of exhaust pipes	Catalytic converter/exhaust system	Surface rust is a characteristic of materials used on exhaust systems. Exposure to heat or road salt may result in surface rust. INSPECT for perforations. If there are no perforations, the condition is normal.