Body problems of the 2024 Ford Bronco

Vehicle: 2024 Ford Bronco outer banks mileage: approx. 15,000 the molded-in-color (mic) composite hardtop panels have developed significant cracking across all four removable roof sections. Cracks are present on the driver-side front, mid, rear, and passenger-side panels. The cracking appears to originate within the composite material and has progressively worsened over time. The vehicle and affected panels are available for inspection upon request. The hardtop is part of a rollover-rated vehicle and contributes to structural integrity and occupant protection. Progressive cracking raises concern about reduced structural performance in a rollover. Additional risks include continued material degradation, potential panel instability at highway speeds, and water intrusion affecting electrical components. The condition has been visually inspected and confirmed by our Ford dealership, which verified cracking on all four panels. The vehicle has not been involved in any accident and has not been inspected by police or insurance representatives. The cracking was not caused by impact, misuse, improper storage, or improper removal. The hardtop has only been removed approximately five times since purchase, with all panels removed together only once, and removal was performed carefully according to manufacturer guidance. The hardtop is currently being replaced under the bumper-to-bumper warranty. However, replacement does not address the underlying concern if the material or manufacturing process is defective. Numerous other Ford Bronco owners have reported similar cracking, including multiple replacements. There were no warning lamps or messages prior to the cracking. The issue was first noticed at approximately 13,000 miles and has continued to progress. Given the low mileage, limited removal, dealership confirmation, and widespread similar reports, this appears to be a potential systemic material defect that warrants further investigation and a permanent corrective act.

Vehicle sustained significant front-end impact in a collision, but none of the airbags deployed. Front bumper, hood, and frame sustained visible damage. Concern that sensors or airbag system failed to activate during qualifying crash.

Removable top cracks allowing moisture to get into effected panels fostering an environment for black mold growth.

Removable top cracks and allows moister into effected panels fostering an environment for possible black mold growth.

Side pillar is blocking view to see if a car is coming, side mirrors do not help. In order to accurately see, you have to completely turn your head to see if you can get over taking your eyes off of the road. This could result in a crash.

There are multiple spots on a 2024 4-door outer banks Bronco (purchased in 03/2024) that are melted. Most of the plastic components of the exterior body of the Bronco are bubbled, warped, or the paint is peeling away from the plastic. See affected areas listed below (see also photos attached). Areas affected: -entire rear side of hard top, including 3rd brake light mount -passenger front mirror -driver's side rear wheel well -top of hard top -passenger's side rear door handle this seemingly occurred over a short period of time (1-2 weeks). This vehicle was taken to three different Ford dealership; the third kept the car for evaluation and inspection for over a week and wrote up an estimate for $14k in replacement parts and $2k for labor. They are unwilling to perform replacements/repairs under warranty as they report this is a problem caused by environmental/external factors and is not a defect of the multiple parts that have melted. This has begun to compromise the integrity of the body of the vehicle, and there would be serious concern for the safety of the vehicle operator as well as others on the road if the deterioration continues to progress.

The left front driveshaft is a problem. Had a 2022 Ford Bronco and Ford did a rav lemon law. Bought a 2024 and now the same problem is happening again. Same issues and 800 miles on a new Bronco. Also on m 2022 had the hard top replaced 5 times and the axle 2 times. And the top now shows cracks with 800 miles as well. Thought Ford would figure it out. Bronco is a great vehicle, just horrible parts. The main thing is the driveshaft I feel be a huge safety issue!!! I hope Ford corporate looks here and gets feedback. By the way, happens after 20 or so minutes of driving, gets warm and it sounds like birds chirping and squeaking.