2024 Ford Bronco Body & Structure Problems

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.

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.

The contact owns a 2024 Ford Bronco. The contact stated that after purchasing the vehicle, it was discovered that the rear trim cover did not sit flush with the soft top roof installed, making the roof unsecure. The manufacturer and local dealer was notified of the failure, but no assistance was offered. The contact was made aware of the NHTSA ID Number: 11001584 (Structure) and related the failure to the NHTSA ID number. The failure mileage was 10.

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 contact owns a 2024 Ford Bronco. The contact stated while pulling out of the driveway two days after purchasing the vehicle, the contact noticed water leaking on the rear seats through the driver’s and the passenger’s side of the roof. The vehicle was taken to the dealer, where it was determined that the water was leaking through the front seals of the roof while the vehicle was parked on an incline with the front of the vehicle facing up. The dealer informed the contact that it was a common failure, and that the vehicle needed to be parked in a different direction to prevent the failure from recurring. The vehicle was not repaired. The manufacturer was notified of the failure and referred the contact to the NHTSA Hotline for assistance. The failure mileage was approximately 35.