Ford Bronco body problems

STRUCTURE:BODY

Cracking of the roof which has caused leaks. Common issue for Broncos, but only recalled for 2021-2022 Broncos. My Bronco is 2023 and has the same issue. It should also be a recall.

NHTSA complaint #11763143 — an unverified report by a vehicle owner.

STRUCTURE:BODY

Front roof panel is cracking and chipping. Rear roof panel is cracking around the side windows. Bronco is never in direct sunlight unless driving. And the vehicle is never driven off-road.

NHTSA complaint #11762533 — an unverified report by a vehicle owner.

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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.

NHTSA complaint #11762457 — an unverified report by a vehicle owner.

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While driving on the roadway at approximately 5,841 odometer miles, the vehicle's fender moulding/flare clip retention failed, causing the moulding to loosen and completely detach from the vehicle. The detached fender moulding separated in transit, creating an immediate road debris hazard for surrounding traffic and trailing motorists. The detached component was recovered with cosmetic surface damage and taken to an independent repair facility for repair and repainting. The component and vehicle remain available for inspection upon request. Prior to detachment, there were no interior warning lamps or messages displayed. The failure matches the defect condition identified under NHTSA Safety Recall Campaign 26V403 (Ford Manufacturer Recall 26S47). The manufacturer's customer support center was contacted to report the failure and seek pre-remedy out-of-pocket repair reimbursement under federal recall guidelines. The manufacturer stated that no reimbursement review or escalation could proceed because the official recall remedy status remains 'Remedy Not Available' (anticipated September 2026), leaving the vehicle owner without a remedy or immediate reimbursement pathway after experiencing the safety failure.

NHTSA complaint #11760981 — an unverified report by a vehicle owner.

STRUCTURE:BODY

Fender flares (2) have detached. Flare 1: Passenger side, front wheel - it flew off while driving. Flare 2: Partially breaking / cracking off - on the drivers side, back wheel.

NHTSA complaint #11758670 — an unverified report by a vehicle owner.

STRUCTURE:BODY

The MIC hardtop is bubbling some at the top and has a line where it looks like perhaps it is assembled on the back panel over the top that is discolored in comparison to the rest of the top. Furthermore, the middle panel is a different color than the rest of the hardtop. It is available for complete inspection upon request. The car has not been inspected by dealer but was bought used and did not show the bubbling whenever it was purchased--but rather it has happened in the months since it was purchased. It was found when the top was removed and the bubbling was noticeable when running my hand over it. Note that it is not visible to be seen via picture, and the bubble must be felt. It cannot be seen in a photo.

NHTSA complaint #11756193 — an unverified report by a vehicle owner.

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The contact owns a 2022 Ford Bronco. The contact stated that the vehicle had experienced issues with hardtop roof panels. The hatch was cracked, and the forward removable panel had developed bubbles. The contact stated that the front driver’s side panel was chipped and detaching, and the underside of the roof was visible. The contact associated the failure with NHTSA Campaign Number: 26V299000 (Structure); however, the VIN was not included in the recall. The dealer was contacted regarding the failure, and the vehicle was repaired under warranty. The manufacturer was made aware of the failure and stated that the roof panel was not under warranty. The failure mileage was approximately 19,073.

NHTSA complaint #11755438 — an unverified report by a vehicle owner.

STRUCTURE:BODY

The hard top is cracking and letting water into the cargo area. It seems to be right outside the parameters for recall number 26S32. Talk to dealer over a month ago and have not heard back yet.

NHTSA complaint #11754241 — an unverified report by a vehicle owner.

STRUCTURE:BODY

The MIC hard top component on my Ford Bronco is cracking. I have gotten it replaced twice through Ford for the same issue, but now this is my 3rd top and the issue keeps coming back.

NHTSA complaint #11751149 — an unverified report by a vehicle owner.

STRUCTURE:BODY

Cracks in left rear of roof theirs a recall ones that painted but not on the matt finish one. My 2022 Ford Bronco 2 door is showing the same problems as the paint ones. And Ford Dealership said they at least a dozen or more around his dealership with the same issue. And online I have been told of 100s. Have the same thing happening to their Broncos the years 2021 to 2024 even ones sit on lots for with the same problems.

NHTSA complaint #11749734 — an unverified report by a vehicle owner.

STRUCTURE:BODY

I notified the dealership where I bought the vehicle of the issue when it first happened in Feb 2025. I have since notified them 3 additional times and I have called Ford Motor Company, twice. The roof leaks in heavy rain while driving and when going through a car wash. The water streams inside and runs down onto the lighted vanity mirror which is connected to the electrical system of the vehicle and hits the driver in the face with water. The dealership said that they tried to reproduce the issue but couldn’t get it to leak. It’s because they aren’t using water at a high pressure and speed. I have since found that the issue is know as it is listed on the internet in multiple places.

NHTSA complaint #11748814 — an unverified report by a vehicle owner.

STRUCTURE:BODY

Ford has issued a recall for 2021- Jan 2022 hard tops. Mine is a June 2022 with the same issues but not listed in the recall. This has been a known issue for the life span of the Bronco.

NHTSA complaint #11746745 — an unverified report by a vehicle owner.

STRUCTURE:BODY

Bronco hard top is beginning to warp really bad and delaminate. Classic problem happening with there and ford still refuses to come up with a real solution. Every day the warping gets worse and I’m just waiting for it to get bad enough so I can take it in and ford actually do something about it. The warping and delaminating also impacts the seals of the hardtop panels on the car. The top also rattles really bad. Absolutely crazy for an expensive car. It’s very obvious that climate and humidity have the largest impact on this issue and STILL they do nothing about it.

NHTSA complaint #11746338 — an unverified report by a vehicle owner.

STRUCTURE:BODY

The Molded-In-Color (MIC) hard top shows signs of delamination and cracking on the exterior skin of the roof panel. Models from the same production year were called under NHTSA Recall No.: 26V299. My vehicle was not included on this recall. I have attempted to have Ford inspect the issue and have refused since it is out of warranty. I am concerned that the delaminating sections will detach while driving.

NHTSA complaint #11743541 — an unverified report by a vehicle owner.

STRUCTURE:BODY

Noticed that my hardtop was cracking around the rear windows. This is a know issue with Ford and is being replaced under warranty. Unfortunately, my vehicle is outside of the original 3 year 36,000 mile warranty period by just over 6,000 miles that would qualify for replacement. The dealer quoted over $10,000.00 to replace the entire top since all roof panels appear to be affected. This is almost 1/4 the cost of my vehicle on the used market and is unacceptable for a know issue that would normally be replaced under warranty.

NHTSA complaint #11739202 — an unverified report by a vehicle owner.

STRUCTURE:BODY

My MIC roof cracked, and I only have 6700 miles on the vehicle. I am now reading that my roof could blow off.

NHTSA complaint #11739222 — an unverified report by a vehicle owner.

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Delamination of roof and cracking with leaks

NHTSA complaint #11739172 — an unverified report by a vehicle owner.

STRUCTURE:BODY

The molded in color hardtops are bad on these Ford Bronco’s. I wanted to report it because mine started cracking, fading, delaminating, and leaking after the vehicle was only 3 months old. They are very defective. Ford warranty replaced mine after a full year of me going back and forth to the dealer to argue about it. It was a long process that I never expected on a brand new vehicle. I’m already starting to see the honeycomb material on my warranty replacement top. I know people who are on their 4th and 5th replacement tops. Also, the road noise is bad with these tops as well. Mine as been warranty replaced now, but it was a rough experience over all and I have zero confidence that the replacement top is of better quality. In fact, the customer service representative at Ford stated more than likely this replacement hardtop would go bad at some point just like the original. They said it was the exact same top with no improvement.

NHTSA complaint #11739158 — an unverified report by a vehicle owner.

STRUCTURE:BODY

This is in reference to Safety Campaign 26S32. My fiancé owns a 2025 Ford Bronco 5 door and her roof has the same exact issue that is described in this safety campaign. Before the vehicle had 5000 miles on it the roof had already begun to show cracks, honeycombing and is beginning to show signs of delamination. The vehicle is going to our local dealer in a week to hopefully have the roof replaced under warranty but I doubt that permanently fixes the issue. Fords comment that they have resolved the issue is patently false. I will gladly send photos of the cracks as soon as possible but this safety campaign, in my opinion, should be extended to all of Broncos from 2021 to current.

NHTSA complaint #11738844 — an unverified report by a vehicle owner.

STRUCTURE

The contact owns a 2024 Ford Bronco. The contact stated that while coming to a stop, the vehicle would unexpectedly lunge forward and hesitate, with no warning lights illuminated. The contact also stated that a loud, abnormal rattling noise was coming from the soft top area of the vehicle. The vehicle was taken to the dealer; however, it was not diagnosed. The contact was informed that the transmission software needed to be reprogrammed. The dealer also stated that the soft top failure is a known issue with the vehicle. The vehicle was reprogrammed, but the failure persisted. The manufacturer was made aware of the failure. The failure mileage was approximately 13,000.

NHTSA complaint #11735534 — an unverified report by a vehicle owner.