Ford Expedition Odors Anyone else?

First of all, our model is a 2002 & it is not from mildew or mold, etc... It is more of a chemical smell that actually burns your nose & eyes.
It doesn't happen all the time. Mostly when the AC is not on automatic & is on recirculation air. The Service dept. has replaced the evap., evap case, & seal. This seemed to help for awhile, but now it is back. I've had it in the garage 6 times & they say they can't find anything wrong that would make this smell. Any ideas on this? It really makes me sick to drive very long in it. Carol
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Carol opined in

FIRST Dont use recirc,
ESPECIALLY on any car with a tailgate
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Why not? I have an Escape and use recirc all the time, both with heat and cool. The humidity here will kill you otherwise, and the summers are so hot, fresh air A/C ain't all that cool. I don't drive with the tailgate or tail window open (like some people do), and I'm sure my seals are good enough to keep any exhaust out. I've never developed a headache on long trips (or short ones either, for that matter), and I don't get any exhaust smell in the car.
SC Tom
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