Component

ENGINE AND ENGINE COOLING:EXHAUST SYSTEM

4,393 NHTSA complaints about engine and engine cooling:exhaust system issues across 51 makes and 633 models.

The engine and engine cooling:exhaust system is one of the standardized component categories NHTSA uses to classify consumer safety complaints. Across the public complaint database, it accounts for 4,393 filings from 51 manufacturers and 633 distinct vehicle models, a footprint large enough that defect engineers can isolate part-family patterns across different platforms that share the same supplier or the same federal motor vehicle safety standard.

Among filings citing this component, owners have reported 72 crashes, 192 fires, 206 injuries, and 8 fatalities. The most complained-about vehicle in this category is the FORD EXPLORER with 189 filings, followed by NISSAN ALTIMA and FORD F-150. These severity counters are what separates a nuisance complaint trend from a pattern NHTSA is likely to escalate into a Preliminary Evaluation.

Component-level analysis is how the Office of Defects Investigation spots cross-manufacturer supplier issues — the same airbag inflator, the same takata-style ignition switch, the same brake hose material — before they become industry-wide recalls. When you see a single component accumulating large complaint volume across several unrelated nameplates, that is usually a signature of a shared supplier or a shared federal standard being stressed by real-world conditions. Use the affected-vehicles table below to see whether the pattern is concentrated on a handful of models or distributed evenly, and cross-reference each model's full recall and investigation history before drawing conclusions about any one nameplate.

4,393
Complaints
633
Models Affected
72
Crashes
192
Fires
8
Deaths

Most Affected Vehicles

# Vehicle Complaints
1 FORD EXPLORER 189
2 NISSAN ALTIMA 180
3 FORD F-150 79
4 NISSAN PATHFINDER 73
5 FORD TAURUS 73
6 TOYOTA COROLLA 67
7 JEEP WRANGLER 64
8 TOYOTA CAMRY 63
9 NISSAN TITAN 61
10 HONDA ACCORD 56
11 MERCURY VILLAGER 51
12 KIA SPORTAGE 51
13 HONDA CIVIC 49
14 VOLKSWAGEN JETTA 47
15 FORD WINDSTAR 45
16 CHEVROLET BLAZER 44
17 NISSAN MAXIMA 43
18 FORD F-250 SD 42
19 TOYOTA 4 RUNNER 41
20 FORD F-250 39
21 JEEP GRAND CHEROKEE 37
22 DODGE RAM 2500 36
23 FORD FOCUS 35
24 VOLKSWAGEN PASSAT 34
25 KIA SEPHIA 34
26 FORD F-350 34
27 NISSAN QUEST 33
28 DODGE RAM 1500 33
29 TOYOTA TUNDRA 32
30 FORD ESCAPE 31

Recent Complaints

2019 SUBARU ASCENT

The contact owns a 2019 Subaru Ascent. The contact stated that while the engine was idling, exhaust fumes entered the cabin of the vehicle. Additionally, immediately after starting the vehicle, there

2018 CHEVROLET TRAVERSE

The contact owns a 2018 Chevrolet Traverse. The contact stated that while driving at 25 MPH, there were exhaust fumes entering the cabin of the vehicle. The check engine warning light was illuminated.

2020 FORD ECOSPORT

The contact owns a 2020 Ford EcoSport. The contact stated that while driving at an undisclosed speed, there was an abnormal odor entering the cabin of the vehicle. The contact stated that the odor was

2025 TOYOTA HIGHLANDER

The contact owns a 2025 Toyota Highlander. The contact stated while driving at an undisclosed speed, there was an abnormally strong odor entering the cabin of the vehicle through the vents. The window

2020 CHEVROLET TRAVERSE

The contact owns a 2020 Chevrolet Traverse. The contact stated that while the vehicle was parked and occupied in the vehicle, there was a rattling sound coming from the front of the vehicle while stat

2024 FORD BRONCO SPORT

The contact owns a 2024 Ford Bronco Sport. The contact stated that while starting the vehicle, there was a ticking sound coming from the engine compartment. There was no warning light illuminated. Add

2021 CADILLAC XT6

The contact owns a 2021 Cadillac XT6. The contact stated that while sitting inside the vehicle, the vehicle felt unbalanced. Upon inspection, the contact noticed that the H-pipe was leaning more to th

2020 RAM 1500

The contact owns a 2020 Ram 1500. The contact stated that while the vehicle was parked or while driving, the contact smelled an abnormal exhaust odor, and there was a rattling sound coming from the ex

2021 BUICK ENCORE GX

The contact owns a 2021 Buick Encore GX. The contact stated while depressing the brake pedal to make a right turn, there was an abnormally loud popping and scrapping sound coming from underneath the v

2016 SUBARU CROSSTREK

Within 24 hours of purchase, the exhaust pipe became detached underneath the vehicle and exhaust fumes and odor were entering the cabin while driving. This created a potential carbon monoxide exposure

2021 CHEVROLET TRAVERSE

The contact owns a 2021 Chevrolet Traverse. The contact stated that while starting the vehicle, the front exhaust pipe made an abnormally loud sound, and there was an odor inside the vehicle. The vehi

2017 CHEVROLET EQUINOX

The contact owns a 2017 Chevrolet Equinox. The contact stated that while driving at 10 MPH, there was an abnormal odor entering the cabin of the vehicle while the air conditioning system was activated

2022 BUICK ENCORE GX

The contact owns a 2022 Buick Encore GX. The contact stated while driving approximately 20 MPH and depressing the accelerator pedal, the vehicle failed to exceed 35 MPH and made an abnormal loud sound

2025 NISSAN ROGUE

The contact owns a 2025 Nissan Rogue. The contact stated that while driving at an undisclosed speed, there was an abnormally strong sulfur odor inside the vehicle. The vehicle was taken to the dealer,

2013 FORD F-150

The contact owns a 2013 Ford F-150. The contact stated that while driving at various speeds, there was an abnormally high-pitched whistling sound coming from the engine bay. The contact was mechanical

2017 NISSAN TITAN

The contact owns a 2017 Nissan Titan. The contact stated that while driving at various speeds, there was an exhaust odor entering the cabin of the vehicle. The contact was forced to lower the windows

2015 SUBARU OUTBACK

The contact owns a 2015 Subaru Outback. The contact stated that while driving at an undisclosed speed, and while at a stop light, there was an abnormal exhaust fumes odor inside the vehicle. There wer

2020 GMC SIERRA 1500

Tick sound coming from underneath. Also fumes smell. Dealership found it to be the exhaust system. Said the muffler valve is bad. Quoted me $2000 for repair. Never heard of a exhaust system failure

2020 CHEVROLET TRAVERSE

The contact owns a 2020 Chevrolet Traverse. The contact stated that while driving at undisclosed speeds, there were abnormal sounds coming from the exhaust system. The contact stated that the vehicle

2018 CHEVROLET TRAVERSE

The contact owns a 2018 Chevrolet Traverse. The contact stated while driving at various speeds, the vehicle was making an abnormally loud sound that became louder over time. The vehicle was taken to a

Frequently Asked Questions

How many complaints involve engine and engine cooling:exhaust system issues?
The NHTSA has received 4,393 complaints about engine and engine cooling:exhaust system problems across 633 vehicle models from 51 manufacturers.
How dangerous are engine and engine cooling:exhaust system defects?
ENGINE AND ENGINE COOLING:EXHAUST SYSTEM issues have been linked to 72 crashes, 192 fires, 206 injuries, and 8 deaths according to NHTSA complaint data.
Which vehicles have the most engine and engine cooling:exhaust system problems?
The most complained-about vehicle for engine and engine cooling:exhaust system issues is the FORD EXPLORER with 189 complaints.
Where does PlainCars get its safety data?
All vehicle safety data comes from the National Highway Traffic Safety Administration (NHTSA) complaints database, which collects reports from vehicle owners about safety-related defects.

Data Sources

Vehicle complaint data from the National Highway Traffic Safety Administration (NHTSA) complaints database. Includes consumer-reported safety issues filed with NHTSA Office of Defects Investigation. Severity counts cross-reference NHTSA FARS (Fatality Analysis Reporting System) for fatal incidents where a corresponding FARS record exists.

Component categories are standardized by NHTSA. Crash-test ratings where shown are drawn from the NHTSA New Car Assessment Program (NCAP). Complaint counts, crash reports, fire reports, and fatality data reflect consumer-submitted reports and may not represent all incidents.

Disclaimer: This data is for informational purposes only and should not be used as the sole basis for vehicle purchase decisions. NHTSA complaint data is self-reported by consumers and has not been verified or investigated. A high complaint count does not necessarily indicate a defect. Always consult a qualified mechanic and check official NHTSA recall notices before making safety-related decisions.

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