What is going on with my exhaust?

[Mavster Mechanic]

OP here again. Is there a phone number or contact at Ford corporate who I can ask if this repair would be covered by the 3-Year Bumper to Bumper?

I would trust Ford Corporate more than my (not so) Friendly Neighborhood Ford Dealer.

EDIT: I found a phone number in the Owner's manual: 1-800-392-3673.

About the only question to answer here is: was this a manufacturing error or was it from over the road damage.

Manufacturing error (tailpipe misaligned) will be covered.

Hitting an object, probably not.
So they will look for any scratches or dents.

Sponsored

 

[not null]

If you wait a couple of months there will probably be a(nother) recall for something. You could get it looked at at the same time.

 

[Chops]

The only two that I found in record were from EcoBoost owners.
Isn't the catalytic converter downstream of the turbos?

Yes, the catalytic converter is downstream of the turbo. GPF, if equipped, is downstream of the cat. Since a turbo extracts heat from the exhaust, the EB 2.0L will typically run cooler at the tailpipe than the naturally aspirated engine like the 2.5L Atkinson.

Either way - after an extended highway drive they can both be as hot a a pizza pan out of the oven

 

[Mavster Mechanic]

New owner of a 2025 Mav XLT AWD Hybrid here and today I poked my head underneath to have a look at the spare tire. Much to my surprise and shock, it sure looks like the hot exhaust from the tail pipe is melting some of the plastic just below it. I've only got 1500 miles on it, mostly highway driving.

What the actual fork?

You made me look.
61,000 miles incl. towing in the Mojave Desert. No melt. Yours is a fluke I think.
Did you once idle against a wall or something that would trap heat?
Not pointing blame. Just like you, I crave an explanation.

 

[Chops]

You made me look.
61,000 miles incl. towing in the Mojave Desert. No melt. Yours is a fluke I think.
Did you once idle against a wall or something that would trap heat?
Not pointing blame. Just like you, I crave an explanation.

Good pic! Notice the difference in gap between yours & the OP’s on the driver side. OP’s is almost touching the plastic and yours isn’t.

Neither are centered with the cut out however - the especially the OP’s.

 

[El Kabong]

Neither are centered with the cut out however - the especially the OP’s.

Neither is mine. It seems the bumper was designed with a dual exhaust possibility that was not implemented.

 

[A112358]

You made me look.
61,000 miles incl. towing in the Mojave Desert. No melt. Yours is a fluke I think.
Did you once idle against a wall or something that would trap heat?
Not pointing blame. Just like you, I crave an explanation.

No long idles at all. (Am I right that the ICE engine doesn't kick in at normal start up until the vehicle is in motion?)

Looking at your photos and the others posted here, my guess is they assembled the bumper with the wrong parts, the plastic piece that melted is way too close to the tailpipe..

 

[El Kabong]

the plastic piece that melted is way too close to the tailpipe..

If you take a look at the hangar, his tailpipe is wedged up in between the hangar (circled it below). This is probably trapping the exhaust against the bed and bumper cover, and yes it does look like it's too far aft, if it was hanging down the isolator would rotate bringing it further forward.

 

[Chops]

Neither is mine. It seems the bumper was designed with a dual exhaust possibility that was not implemented.

I think most (all?) of our Mavericks are a bit off center of cut out. Bumper needs to be redesigned. Ford can add it to their list haha.

Here is what the cutout looks like on the spare bumper I have on my garage wall…ignore the bungee cord in the cutout holding it up….

 

[El Kabong]

Edit: Another one
Somebody did a dual exhaust tip

 

[mwbaumannmo]

New owner of a 2025 Mav XLT AWD Hybrid here and today I poked my head underneath to have a look at the spare tire. Much to my surprise and shock, it sure looks like the hot exhaust from the tail pipe is melting some of the plastic just below it. I've only got 1500 miles on it, mostly highway driving.

What the actual fork?

My 2025 Hybrid is 10 months old and 1600 milles. Attached are 2 files to get a reference where the pipe should be aligned. No burning on my plastics. You should also consider that the exhaust is running extra hot for some reason. Seems too far away to melt the plastics.

 

[mwbaumannmo]

New owner of a 2025 Mav XLT AWD Hybrid here and today I poked my head underneath to have a look at the spare tire. Much to my surprise and shock, it sure looks like the hot exhaust from the tail pipe is melting some of the plastic just below it. I've only got 1500 miles on it, mostly highway driving.

What the actual fork?

 

[A112358]

OP here again. I had a mechanic friend (Chevy) who lives up the street take a look at it. His opinion is that it looks like something hit that piece of the bumper. Well, there is no way in hell in the 1500 miles I've driven it that I ran over anything big enough to hit the underside of the bumper like that. It's 17" off the ground.

The only conclusion I can think of is that the damage was done at the factory or at the dealership. I did inspect the vehicle before I signed on the bottom line to buy the vehicle, but honestly I did not look underneath. Nothing was apparent in the test drive.

If I complain about the damage, I'm sure the factory or the dealer will deny it and just say I did it, which I didn't.

I'm afraid I'm just going to have to bite the bullet and live with it. It's not interfering with anything and the damage is only noticeable from underneath. I'm not going to pay big bucks to get it repaired. If I get motivated. I may get under there with a jigsaw or oscillating tool and clean it up a bit.

Thanks for all the input and photos from everyone.

 

[Meeka]

My 2025 Hybrid is 10 months old and 1600 milles. Attached are 2 files to get a reference where the pipe should be aligned. No burning on my plastics. You should also consider that the exhaust is running extra hot for some reason. Seems too far away to melt the plastics.

What’s the point of having the “bumper cut out” when they can’t even get the tailpipe aligned to it properly? Assembled by “one eyed Joe”! My 24 is off centre too. 🫩

 

[Chops]

What’s the point of having the “bumper cut out” when they can’t even get the tailpipe aligned to it properly? Assembled by “one eyed Joe”! My 24 is off centre too. 🫩

The lower hanger bracket welded to our tailpipes is too short. Needs to be about an inch or so longer for the tailpipe align properly with the cutout.

Sponsored