2021 Ford Bronco Body & Structure Problems

Component/System Involved: Molded-in-Color (MIC) Hardtop – Composite Roof Panel What happened: The molded-in-color (MIC) hardtop on my 2021 Ford Bronco (2-door) has developed multiple visible stress cracks above the passenger-side window. These are not surface scratches — they are embedded, structural fractures in the composite roof material. The cracks have formed under normal, garage-kept driving conditions at just over 10,400 miles and continue to worsen. Safety risk: I am concerned these cracks pose a potential safety risk, particularly involving water intrusion during rainfall or car washes. The affected area is directly above the front-row passenger seat and adjacent to electrical systems, including interior lighting and airbags. If water penetrates the roof structure, it could lead to mold, short circuits, degraded visibility, or electrical malfunction — especially under motion. Additionally, the structural integrity of the hardtop could be compromised in a rollover scenario. Inspection history: A Ford dealership in Winchester VA acknowledged this is a known issue and stated they had replaced multiple hardtops for the same defect. However, they declined to inspect my vehicle due to the warranty having recently expired. Ford Motor Company also reviewed the issue but denied coverage without inspecting the vehicle. Manufacturer acknowledgment: Ford delayed delivery of my Bronco by over a year due to widespread MIC hardtop defects. Despite that delay, the same failure has now occurred in my vehicle, just beyond the warranty period and with low mileage. Inspection availability: The vehicle and affected hardtop are available for inspection upon request. I have detailed photographs showing the extent and location of the cracks. Symptoms and warnings: There were no warning lights or error messages prior to the appearance of the defect. The cracks appeared gradually and became visibly obvious in June 2025.

The contact owns a 2021 Ford Bronco. The contact stated the rear translucent heavy plastic panel was loosened due to the breakdown of the plastic tabs used to secure the rear panel in place. The contact stated that the vehicle was equipped with a soft top, and when the weather was warm, the side panels and rear panel would be removed to open the rear of the vehicle like a convertible. The contact was concerned that the clear panel could fall from the rear of the vehicle and strike the vehicle behind. The contact had taken the vehicle to a local dealer, where it was diagnosed and determined that the soft top needed to be replaced. The vehicle was not repaired. The contact stated that prior to the failure, the soft top had been replaced because the side clear panels had experienced a similar failure with the plastic tabs. The manufacturer was informed of the failure and referred the contact to the NHTSA Hotline. The failure mileage was approximately 38,000.

Vehicles top is cracked and delaminating witch could come off in large sheets and cause harm to other vehicles and pedestrians The dealership got a rejection letter from ford and is resubmitting the claim again I was told they had another one in not too long ago with the same issue and they warranted it I need to drive the truck and am concerned about causing harm or damage to other vehicles or drivers

The contact's daughter owns a 2021 Ford Bronco. The contact stated that the sides of the soft top material above the B-pillar and the A-pillar were detaching, which could cause the soft top to separate from the vehicle while driving. The vehicle was taken to the dealer, where it was inspected, and the dealer determined that the soft top needed to be replaced. The vehicle was not repaired. The contact related the failure to TSB Number: 23-2229. The manufacturer was notified of the failure and informed the contact that there was no guarantee that assistance would be provided in covering the cost of the repair. The manufacturer referred the contact to the NHTSA Hotline for assistance. The failure mileage was approximately 48,000.

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.

The contact owns a 2021 Ford Bronco. The contact stated while the vehicle was parked, the contact discovered that the removable hardtop was cracked. The vehicle was taken to a dealer where it was determined that the removable hardtop needed to be replaced. The contact researched and was made aware of an undisclosed recall; however, the VIN was not included. The vehicle was not repaired. The manufacturer was notified of the failure and referred the contact to the NHTSA Hotline to report the failure. The failure mileage was approximately 25,000.

The contact owns a 2021 Ford Bronco. The contact stated while driving 55 MPH, the contact heard an abnormal popping sound from the rear of the vehicle. When the contact stopped at his destination, he observed that the rear removable soft top had come loosened, and the plastic clips used to hold the soft top in place had fractured due to the force of the air blowing over the roof of the vehicle. The contact had not taken the vehicle to a local dealer or independent mechanic. The vehicle was not diagnosed and was not repaired. The contact stated that the failure had occurred for the second time and had been previously repaired a year prior. The manufacturer was informed of the failure. The contact researched online and related the failure to Technical Service Bulletin Number: 23-2091 Loose Exterior Fabric on Rear Window (Structure). The failure mileage was 42,725.

The contact owns a 2021 Ford Bronco. The contact stated while driving 45 MPH, the rear window clips fractured, causing the window to detach and fall onto the roadway in traffic. No warning light was illuminated. The vehicle had been diagnosed by the dealer and determined that the failure was the depillar clip. The vehicle had not been repaired by the dealer because the part was not available. The manufacturer was made aware of the failure and determined that the part was not yet available. The failure mileage was approximately 19,000.

water is leaking from the passenger side roof through the passenger side door airbag when it rains. The passenger side top door airbag is constantly getting wet from this leak as water passes through.

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.