Hole in Muffler from factory?

[013SamIAm]

Just a thought I only show one muffler for the hybrid and two separate ones for the 2.0. Maybe the one's with the hole are 4wd and the one's without are 2wd?!?

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[Probity]

As others have mentioned:

1. Water draining from muffler weep holes is normal. Almost all modern vehicles have intentional muffler weep holes. Google 'muffler weep hole' and you'll see references for almost every car manufacturer. A typical result - from What are the Effects of Having a Hole In Your Muffler? - In The Garage with CarParts.com

2) Carbon (i.e. 'soot, or ultra-fine particulate matter - PM) on exhaust - again, normal to see on tailpipes for direct injection (DI) engines like the 2.0EB. With the Hybrid 2.5L Atkinson engine (port fuel injection, PFI) you should not really see much 'soot' at the tailpipe. The black stuff around the muffler weep hole obviously a product of combustion that the water condensation captures. Not that unusual in my view.

Gasoline DI engines produce more 'soot', that's their nature. If you want to get down in the weeds a little, some slides from a Ford guy - PowerPoint Presentation (healtheffects.org) . It's ironic; DI engines increase fuel economy and decrease CO2 emissions (good enviro stuff), but pump out more particulate matter (bad enviro and health stuff).

Be thankful in the US we generally haven't gone the GPF (gasoline particulate filters) route for DI engines like in Europe. GPF's reduce 'soot' but tend to decrease fuel economy. For those of you with utility tractors with Tier 3/4 diesel engines, you know the "joys" of having to periodically going through the diesel particulate filter regen cycles (that 2000+ deg. F. fire source in the engine bay).

I was able to directly observe some of this. I had a 2016 F-150 with the 3.5EB engine (DI only). Did a fair amount of city driving. Chromed tailpipe tip easily showed soot accumulations between washings. In 2017 or 2018, Ford changed their F-150 EB engines (2.7EB and 3.5EB) to a combo port fuel injection/direct injection (PFI/DI) design. At lower speeds they are mainly PFI, at higher speeds DI. They did it mainly for particulate matter reduction especially at lower (city driving) speeds. Traded the 2016 F-150 for a 2018 with the 'new' 2.7EB with combo PFI/DI. Now, little to no observable 'soot' on the chrome tailpipe at all. It works.

I believe the Maverick 2.0EB is DI-only so not surprising that soot is more noticeable.

 

[pxpaulx]

I think the real solution here is to cut the muffler out and put a straight pipe

 

[PNWMaverick]

I think the real solution here is to cut the muffler out and put a straight pipe

Cat delete with straight pipes. Run some cutoffs to 6" dumps right off the headers for when you really want to make some noise.

"Mommy! Why is the little truck so angry?!"

 

[FORD BOSS ME]

Hi! I picked up my truck last Saturday and so far its been a blast. We just did an 870 mile road trip from Maine to Philadelphia this past weekend. This morning starting my Maverick I noticed exhaust coming from the muffler with what looks like a punch through hole. I think it might of been done at the factory with how clean it looks, like a precision cut. I have an appointment friday to get it looked at and probably replaced with the warranty. So far I have no exhaust smell in the cabin, smell of something time to time I think is break in Has anyone else had this issue? I’ve attached some photos and a video. My Maverick has 1100 miles.

Completely Normal

 

[FORD BOSS ME]

Hi! I picked up my truck last Saturday and so far its been a blast. We just did an 870 mile road trip from Maine to Philadelphia this past weekend. This morning starting my Maverick I noticed exhaust coming from the muffler with what looks like a punch through hole. I think it might of been done at the factory with how clean it looks, like a precision cut. I have an appointment friday to get it looked at and probably replaced with the warranty. So far I have no exhaust smell in the cabin, smell of something time to time I think is break in Has anyone else had this issue? I’ve attached some photos and a video. My Maverick has 1100 miles.

All exhaust systems have little weep holes strategically place through out the exhaust, I'll make a video on it tomorrow and explain - depending on climate and how.long the vehicle is in open loop will determine how the Internals look but that little black fueling is what's coming out and it's normal.

Hotter climates won't see it as much but still possible

 

[FORD BOSS ME]

@FORD BOSS ME says don't summon me again unless you ready for that pain

No pain just honesty

Sorry Fellas been super busy, got.covid and then swamped at work and then had to put two of our cats down almost back to back and been searching for home and found one and cranking out YouTube videos

Now I get a message tonight from someone saying they work at corporate and are interested in pulling me on board with them.... let's see what happens and then I'll really have complete access to help keep people up to date in the community

 

[tomahawk72]

All exhaust systems have little weep holes strategically place through out the exhaust, I'll make a video on it tomorrow and explain - depending on climate and how.long the vehicle is in open loop will determine how the Internals look but that little black fueling is what's coming out and it's normal.

Hotter climates won't see it as much but still possible

Thank you for responding, and I look forward to your video! I have not noticed any issues with it and I currently have 2500 miles on my Maverick. I used to own a 2012 CRV and I never noticed smoke like this out of the muffler, either because I wasn't paying attention or because it wasn't as smokey during cold starts as a DI engine.

 

[Mavonorder]

I guess the big question is: why on some but not on all?

The ones with the holes obviously got the spray in bed liner and the line worker used an extra long drill bit to tap out the drain holes in the bed, and those without the holes in muffler either didn't get the spray in liner, or the line worker used a shorter drill bit

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