2023 Ford Bronco Body & Structure Problems

Chronic water leak from roofline obstructing vision and causing confusion while underway

The contact owns a 2023 Ford Bronco. The contact stated that upon inspection the hard top roof, there were several cracks formed on the roof. The vehicle was taken to the dealer where the failure was acknowledged, and it was agreed that the hard top would be replaced under warranty. After the hard top was replaced, the contact inspected the new hard top and discovered several dents and uneven surfaces on the roof. The dealer was notified of the failure, and an agent advised the contact to bring the vehicle back to the dealer. The contact was informed that he could inspect the hardtops of the newer vehicles at the dealer lot and if he found a top that he liked, the dealer would swap the hardtop and replace the hardtop. After inspecting approximately 5 vehicles, each vehicle had issues with their hardtops. Upon investigation, the contact discovered General Service Bulletin: 23-7174, which was associated with the failure. The manufacturer was not notified of the failure. The vehicle was not repaired. The failure mileage was approximately 18,000.

The contact owns a 2023 Ford Bronco. The contact stated that after opening the driver's side door and then closing the door, the passenger's side hard top fractured into several pieces. The dealer was contacted and informed of the failure. The dealer confirmed that the repair would not be covered for free. The vehicle was not diagnosed or repaired. The manufacturer was informed of the failure. The manufacturer confirmed that the repair would not be covered. The manufacturer opened a case regarding the failure. The manufacturer referred the contact to the NHTSA Hotline to report the failure. The failure mileage was approximately 11,000.

rear tailgate on the bronco gives off a very loud rattling noise when driving

Factory hard top developing cracks around the corner of the back window on the passenger side. Vehicle is still under the 3-year / 36,000 mile factory warranty. This is the first instance that I have experience with this type of cracking on the factory hard top, and appears to be a known issue to Ford Motor Company since they have issued a General Service Bulletin (23-7004) regarding this type of issue. I am in the process of having the vehicle inspect by local Ford dealership for warranty claim. As a consumer, I do have concern about the long term durability of the hard top or any factory replacements. There are numerous examples of owners that have had multiple hard top replacements under the factory, in some cases 3-4 hard top replacements, prior to exhausting the 3 -year /36,000 mile factory warranty. These cracking issues associated with this hard top can present at different points in the part lifetime; In some cases within a few hundred miles and in others, not until the vehicle has surpassed the factory warranty. Regardless of lifespan, which does appear to be much short than a consumer would expect, The greatest concern I have as a consumer is the potential for this part to suddenly and unexpectedly fail without warning, and potential risk that could have on the vehicles' occupants or other vehicles on the roadway. The inner core of these factory hard tops are made come a cardboard composite material; Ford has stated the cracks are generally cosmetic in nature, but myself, as well as numerous other owners, have concern that with time, if moisture penetrates the hairline cracks, the cardboard may cause unexpected deteriorate enhancing risk for part failure. This gives consumer a false sense of safety and security. Ford should be finding a long term solution to this issue instead of replacing factory hard tops replacements of the same kind that also fail. It is a matter of time before injury or death occurs due to Ford's lack of a long-term solution.

The contact owns a 2023 Ford Bronco. The contact stated while the vehicle was parked, the contact noticed that the hard top was detaching. The vehicle was driven to the dealer but was not diagnosed nor repaired. The manufacturer was notified of the failure. The failure mileage was 45,000.

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

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 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.