Migraine headaches, fatigue and dizziness were sidelining Bert Henriksen several times a week. Evenings were the worst, after his 30-mile commute home in his 2017 Ford Explorer.
His behavior grew erratic. He’d get angry over minor things. “We were getting scared that he had some kind of a brain problem,” said his wife, Megan.
An answer came last March in a phone call from his doctor: A blood test revealed that Henriksen had been exposed to toxic levels of carbon monoxide gas. But how? The result was consistent with someone who’d been in a house fire, his doctor said, but Henriksen hadn’t been through anything like that.
He says his prime suspect was parked in his driveway.
Henriksen is among more than 3,000 Ford Explorer owners who’ve complained to Ford or federal regulators that they suspect exhaust fumes have seeped into their sport-utility vehicles’ cabins. Many fear carbon monoxide gas may have made them ill, and dozens of drivers have complained to regulators that the company’s recommended fix wasn’t effective. Explorer owners have filed more than 50 legal claims nationwide against Ford. And some police departments in the U.S. said in 2017 that Explorers used as cruisers were exposing officers to carbon monoxide.
The complaints, which cover vehicles built between 2010 and 2018, carry high stakes for the second-largest U.S. automaker. The National Highway Traffic Safety Administration began investigating drivers’ claims in 2016, then expanded the probe a year later after saying it had “preliminary evidence” of elevated carbon monoxide levels in some driving scenarios. If NHTSA finds a safety defect, Ford would face the prospect of recalling more than 1 million vehicles, costing perhaps hundreds of millions of dollars.
Ford, which in January debuted a redesigned Explorer for the 2020 model year, says there’s nothing wrong with the previous version. “All of our testing to date has shown these vehicles are safe,” company spokesman Mike Levine said in a statement. “Ford’s investigation has not found carbon monoxide levels that exceed what people are exposed to every day.”
The claims aren’t easy to investigate. For one thing, hospitals and doctors seldom test patients for exposure to carbon monoxide—Henriksen’s test was rare. Also, the U.S. has no regulatory standard for how much of the odorless, colorless, toxic gas would create a health risk for drivers, and scientists say the answer varies depending on individuals’ health and age. And drivers say the seepage problem comes and goes, complicating attempts to verify their allegations.
NHTSA’s task includes evaluating both what might be causing the alleged defect and what sort of health risk is posed to occupants by any pollutants in the cabin, a subject that global experts have just begun to study in recent years.
The fact that the agency’s investigation is well into its third year is “extraordinary,” said Allan Kam, an independent auto-safety consultant who retired as a senior enforcement attorney at the agency in 2000. It may signal that the probe isn’t a high priority—or it may reflect resource constraints at NHTSA’s Office of Defect Investigations, Kam said.
“It could be a serious problem,” he said, “and because it’s not like a crash where there’s an obvious impact or moment of danger, this is something that builds up over minutes but potentially could be very serious or deadly.”
Ford’s response to the claims has served to deepen some drivers’ mistrust. The company’s first attempt to quell the concerns—through repair instructions the company provided to dealerships in 2012 to respond to customers’ complaints—was followed by repeated updates and several additional instructions. Ford said it’s confident in its most recent repair campaign, which was offered in 2017 and is still in effect. Complaints have dropped dramatically since this latest effort, the company said, and the fix “effectively resolves the matter.”
And yet, for drivers like Bert Henriksen, it hasn’t. He now drives with a portable carbon monoxide detector in his Explorer, and he said it occasionally shows elevated levels of the gas. He invited Bloomberg News along for a ride.
There was very little sign of carbon monoxide during a 76-mile test drive near Henriksen’s home in South Lyon, Michigan, in January. One of two detectors in his vehicle registered only tiny amounts of the gas. The other showed zero.