my Ford Explorer Fifth Generation (2011-2019) is making a loud exhaust noise

Ford Explorer Fifth Generation (2011-2019)

Error Codes

2-4 hours

Time

medium

Difficulty

medium

Severity

3 min read

489 words

Problem Statement

Learn how to diagnose and fix loud exhaust noise in Ford Explorer Fifth Generation (2011-2019). Step-by-step guide with diagnostic procedures and repair instructions.

Affected Component

Exhaust System

Estimated Time

2-4 hours

⚠️ Safety Warnings

Important safety information - read before proceeding

•Disconnect the battery before working on electrical components.
•Allow the engine to cool completely before beginning work on the exhaust system to prevent burns.

Symptoms

•Loud or rumbling noise from the exhaust system
•Decreased engine performance or power
•Check engine light illuminated
•Unusual vibrations felt inside the cabin
•Increased fuel consumption
•Strong exhaust odor

Diagnostic Steps

1
Inspect the exhaust system visually for any visible damage or loose components.
2
Use an OBD-II scanner to check for any stored error codes related to the exhaust system.
3
Listen for noise sources while the engine is running, checking for leaks or holes in the exhaust.
4
Check the condition of the exhaust hangers and mounts for wear or breakage.
5
Examine the catalytic converter for signs of damage or blockage.
6
Inspect the muffler for corrosion, punctures, or other signs of failure.

Solution

💡 Expert Tip

For complex repairs like this, consider taking photos at each step. This helps if you need to reverse a step or consult with a mechanic. Also, keep all removed parts organized - you may need to reference them during reassembly.

Verification

After completing the repair, verify that the issue has been resolved:

✓Test the affected component to ensure it functions correctly
✓Check for any error codes or warning lights
✓Monitor the vehicle for a few days to ensure the issue does not recur

Prevention Tips

To prevent this issue from occurring again:

•Follow the manufacturer's recommended maintenance schedule
•Address warning signs early before they develop into major issues
•Use quality parts and fluids recommended for your vehicle
•Keep detailed records of all repairs and maintenance

Tools & Equipment Required

•OBD-II scanner
•Socket set
•Torque wrench
•Jack and jack stands
•Screwdriver set

Parts Required

•Exhaust hangers
•Muffler (if damaged)
•Catalytic converter (if damaged)

Related Faults

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Diagnostic Steps

1
Inspect the exhaust system visually for any visible damage or loose components.
2
Use an OBD-II scanner to check for any stored error codes related to the exhaust system.
3
Listen for noise sources while the engine is running, checking for leaks or holes in the exhaust.
4
Check the condition of the exhaust hangers and mounts for wear or breakage.
5
Examine the catalytic converter for signs of damage or blockage.
6
Inspect the muffler for corrosion, punctures, or other signs of failure.

Solution

1. Preparation

Gather tools and parts needed for the repair.
Ensure the vehicle is parked on a flat surface and the engine is cool.
Raise the vehicle using a jack and secure it with jack stands.

2. Inspect and Repair Exhaust Components

Exhaust Hangers:
1. Inspect the exhaust hangers for cracks or breaks.
2. If damaged, remove the old hangers using a socket set and replace with new ones.
Muffler and Exhaust Pipes:
1. If the muffler is damaged, remove the exhaust clamps and disconnect the muffler from the exhaust pipes.
2. Replace the muffler with a new one, ensuring proper alignment and fit.
3. Reattach using new clamps or bolts, torquing them to the manufacturer's specifications (typically around 15-25 ft-lbs).
Catalytic Converter:
1. If the catalytic converter is found to be damaged, disconnect the upstream and downstream exhaust pipes.
2. Remove the catalytic converter using a socket set.
3. Install the new catalytic converter and reconnect the pipes, again torquing to specifications.

3. Final Checks

After repairs, recheck all connections for tightness and any signs of leaks.
Lower the vehicle and start the engine to listen for any remaining noise.