I have a 2006 5.4 with 130,000mi. I recently got a camper and pulled it a few times with no smells or issues (actually, the truck performed very well). On my last trip to a campground close by (only about 20 mi away) I smelled a burning rubber smell when driving. The smell was not present when idling or when truck was off, but returned when driving. I immediately stopped and inspected everything. There was no smell under the hood, by the tailpipe, by the truck tires, or by the camper tires. The smell was not detectable anywhere. I disregarded the smell and thought it was just some road rubber on the tailpipe or some other external outdoor smell. We camped two nights and hooked up the camper to drive home and smelled it again when driving. When I got home, again, nothing could be found anywhere and no smell was present. I just changed spark plugs and COPs about a month ago. I pulled my trans dipstick and the fluid isn't gritty with no smell or burnt color. I'm baffled as the truck performs well and no signs of issues, but the smell is horrid. Any ideas would be greatly appreciated. Thanks.

 

Was the smell inside the truck? Were the windows up or down?

I'm afraid I can't offer any advice, but I'm curious as to the cause. Hopefully someone else may be able to point you in the right direction.

 

My windows were down. The smell was outside of the cab. I haven't pulled the camper since that outing. I'm probably going to hook it up and pull it around to see if it returns, but wanted to get some ideas before that was done.

 

Could it have been brakes overheating? Possibly the emergency brake was stuck. Also, could it have been the transmission overheating and fluid overflowing, getting on the exhaust?

 

I was going to guess what Jim mentioned, some kind of stuck/dragging brakes.

I would suggest checking it again on a day with calm winds. If the smell comes back, make sure you try to locate it from the downwind side. (I hate to state something so obvious, but it's all I have to offer.)

 

Brakes were my first guess too. I couldn't see any signs on the TT or truck of this occurring when immediately inspecting. After I unhooked the camper I drove the truck around and no smell was present. It seems like for some reason during the short trip something caused the smell. My next thought was the trans. How can I tell if there's an issue when I don't have a trans temp gauge? Would a fluid replacement and filter change be a good idea (not flush)? It has never been changed, but the fluid appears fine. Doesn't Ford recommend a change every 100,000 mi?

 

I overloaded my truck with rocks in the bed and it was making a noise and smelt like rubber burning

 

There wasn't any noise, dash lights, or signs of distress. Just a smell.

 

I was going to say check your tow package (if equipped). Maybe the brake control was set up to where the trailer was locking up? Just a thought

 

Might be a long shot and tough to track down but could it be that when fully loaded the truck settled enough (front or back) that something is rubbing ? Something that normally clears without any added weight. That or some overheating under the hood as mentioned. I'd check the front first as you mentioned windows down and only while moving, without a tail wind it seems unlikely the smell could be coming from behind the cab.

 

These are great ideas, I'll make sure and check. Thanks alot.

 

I completely agree. I assumed that he was driving a stop-and-go route (intersections, lights, turning, etc.), which may have allowed a wind-shift to carry the smell into the window.

If the smell was present without stopping or turning, then I would definitely start up front.