Body Problems of Ford Bronco - part 2

I am writing to report a serious safety issue with my 2021 Ford Bronco. While driving on the highway at approximately 55-60 mph in the early morning, I heard a loud noise and saw powder falling on me. Upon pulling over, I discovered that a large section of my hardtop had blown off. Specifically, the plastic part over the fiberglass detached. If there had been a car behind me, it would have certainly been struck by the debris. This incident poses a significant danger not only to me but to other motorists as well. Ford is aware of this issue but has refused to address it. I consider this a critical safety hazard and request that this matter be investigated promptly. I believe the manufacturer should replace the defective hardtop and take responsibility for ensuring the safety of their vehicles. Any assistance in resolving this issue would be greatly appreciated. Thank you for your attention to this urgent matter.

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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.

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The front flares at highway speeds blow off-Ford has known about this issue and refuses to acknowledge this issue that is very well documented on the Ford Bronco raptor forums. The do not warranty these even though there is only a few thousand miles, they will not even give a reason why they deny the warranty. This is a safety issue as they are only held on with a few clips. These are oversize flares and the wind from hwy speeds causes the flimsy clips to break making the oversized tire flares to fly off.

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The hardtop developed cracks early on during the life of the vehicle. It leaks water. It’s a known issue with Bronco owners with the factory hardtop. Some people have had it replaced more than 3 times due to the same thing continuing to happen.

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Hard top rear section delaminating due to unfinished edges allowing moisture to enter Ford offered to cover all but $1200. 00 being the vehicle now has over 40000 miles believe it's a manufacturer defect should cover all cost.

4 door hardtop roof leaks. It is available. There is nowhere, including Ford website, to report non-safety defects.

Hard top is unlaminating around rear fixed windows at around 40000 miles Ford offered to pay a portion this is not an isolated issue.

The hardtop is failing in a critical mounting point location. Stress cracks are forming on the exterior of the hardtop directly parallel to the interior mounting bolts. The vehicle has 1,500 miles. The risk of the hardtop failing to remain attached to the vehicle on the road due to structural cracks is the safety concern. For structural cracks to occur within the first 1,500 miles does not imply future safety of passengers or others on the road. The problem has been documented by a local Ford dealer that deemed this is not a warrantable condition. The cracks began to appear before the first 1,000 miles of ownership. This vehicle was purchased new and is 5 months old. There were no other symptoms prior to the failure. With how quickly the cracks appeared the concern is sudden and imminent failure while driving.

The rear hardtop panel on my 2022 Ford Bronco has developed serious cracking and surface separation after only three years of light, garage-kept use. The fiberglass is fracturing near the seams, exposing the underlying material. Water is now visibly collecting in the openings, which will lead to internal moisture intrusion, mold, and eventually corrosion of structural components underneath the hardtop mounting area. This poses a serious long-term safety concern, especially in the event of rear impacts or rollover situations. A Ford dealer inspected the issue and submitted a warranty claim, which was denied. The Ford representative acknowledged the damage but said they could not act without a recall or broader investigation. No warning lights or messages appeared; the issue is external and has progressed gradually. The damage began well before my bumper-to-bumper coverage expired, but has recently worsened. Ford’s own general service bulletin gsb 23-7174 lists rear hardtop panel cracking and edge delamination as warrantable conditions. My panel clearly fits those descriptions. Still, I was quoted nearly $10,000 for a full replacement, which is unreasonable. This is not an isolated case. Many 2021–2022 Bronco owners have posted identical problems online. Ford is clearly aware of this issue—which is why they issued that bulletin—but is denying claims unless pressured through complaints. I believe this is a materials or manufacturing defect and ask NHTSA to investigate this clear and ongoing failure.

The windshield was faulty upon delivery of our new 2 door Ford Bronco. Every time it rains, water pours inside the vehicle through the gaps in the windshield sealant. The water flows through the passenger side a-pillar, and comes out of the airbags, as well as the defrost vents, then flowing down the side of the dashboard, and landing on the front passenger floorboard. The service department had to replace the entire front passenger side a-pillar during our most recent visit. The windshield is a major structural component of a vehicle, and our dealership service department confirmed that our faulty windshield puts our safety and the safety of our passengers in danger of experiencing serious injury when the windshield sealant completely fails. We have been to the dealership twice for the water intrusion caused by the faulty windshield. The Ford service department staff said Ford has previously issued a recall for this exact issue, but the recall is not for our specific model, so the Ford service department was not able to replace our faulty windshield under warranty. The inability of the dealership to replace our faulty windshield under warranty forced us to make an insurance claim and replace the windshield on our own. Upon installing the new oem windshield, the technician pointed out to us in person where the faulty windshield issue stemmed from. It is obviously clear that Ford never tested our vehicle's windshield sealant gaps before they shipped it out for delivery. If they did not test our windshield structure, there could be many other 2023 Ford Bronco 2 door models delivered with faulty windshields. Note: we have never taken our vehicle to any kind of car wash, as the owner's manual is very clear about avoiding these. We have also never removed any of the roof panels. Process of elimination removes both of these situations as secondary causes for water intrusion.

Stitching and seals on the soft top have separated creating concern over large tear that could separate the soft top material from the frame and cause a safety issue. Brought this to the attention of the local dealer and said it would be addressed but they failed to address issue with return communication from dealer. Took to another dealer and Ford refused to repair despite it being approved previously and the stitching separating even further. The vehicle has been well maintained and not abused in any form or fashion. This is a concerning issue.

After exposure to rain, driver's side floods with water coming from a-pilliar, air bags or windshield.

My 2022 Ford Bronco 2 door hard top has wind (air leak) noise where the t-top joins the hard top. The weatherstripping does not properly seal causing wind noise, possible water intrusion (potential mold issue). This wind noise has been brought to the attention of the dealer and Ford's regional field engineer. The wind noise can cause hearing problems but not hearing emergency vehicles, and potential heating loss. The voids in the weather stripping can allow water to enter interior causing a mold issue. The factory has replaced the hard top once, but the issue still persist. This is a common problem with hard top Broncos.

Passenger and driver windows severely rattle/vibrate/shack when windows are open.

The contact owns a 2021 Ford Bronco. The contact stated after the vehicle was parked in the rain, he noticed on the passenger’s side a-pillar, where the air bag marking was located that water was leaking into the vehicle. No warning lights were illuminated. The vehicle was taken to the dealer where the cause was discovered as a clip was damaged allowing the water to get into the a-pillar. The dealer repaired the failure by adding additional sealant to the area. The contact stated he looked at the repair and contacted the dealer stating the repair was not proper. The dealer informed the contact that a TSB was recently issued for the failure. The contact was waiting for an appointment as parts needed to be ordered to repair the failure. The manufacturer was notified, and a case was opened. The approximate failure mileage was 600.

I was heading to the store when my gas pedal for stuck. I pressed the brakes and held them down to no avail. I ended up crashing through someones yard and hitting their property. My Bronco finally stopped about 15 seconds later. The whole incident was about two minutes long.

I am writing to formally complain about a serious and increasingly concerning problem with the hardtop on my 2022 Ford bronce four-door. I began noticing cracks in the hardtop after becoming aware of numerous complaints from other Bronco owners regarding similar cracking problems. Once I knew what to look for, I inspected my Bronco and noticed cracks in the hardtop. I promptly brought the issue to the attention of my Ford dealership. Unfortunately, I was told that the vehicle had just passed the time limit of the factory warranty, even though it was well within the mileage limit of the warranty. I find it extremely frustrating that Ford’s position appears to be based on the calendar expiration of the warranty when this is a known problem (defect) that has been reported by numerous Bronco owners. More importantly, the condition of the hardtop has deteriorated significantly. Over the past several months, the cracks have become substantially worse, and I am now concerned that the hardtop could eventually fail completely. This is no longer simply a cosmetic concern. I purchased a new Ford Bronco with the expectation that the vehicle’s major structural components would remain reliable under normal use. I am requesting that Ford reconsider my case and provide full replacement of the defective hardtop at no cost to me, including parts and installation cost. I would also like Ford to consider the safety implications of allowing a hardtop with progressively worsening cracks to remain in service. I have legitimate concerns that the hardtop could fail at speed or during an accident creating hazard or injury.