Ford Bronco Owners Noticing Issues With Molded Roof

Matt Posky
by Matt Posky

A few Ford customers are expressing concerns about the quality control of the new Bronco after noticing the molded hardtop seemed to be coming apart prematurely. The issue impacts an unknown number of early vehicles, with only a handful of owners suggesting they’ve noticed anything. However, those that are sounding alarm bells noted that the vehicle seemed put together when they purchased it, with the defects manifesting after a few weeks of regular use.

Problems include the headliner separating from the roof panels and some discoloration at the seams. But the signature defect appears to be scales appearing on the hardtop’s exterior. While smooth to the touch, members of the Bronco6G forum reported that their roofs had developed patterning that resembled snakeskin in some areas — attributing the phenomenon to the outer laminate layer being cast too thin.

That’s not yet been proven but seems a plausible enough explanation. It’s the kind of thing that probably looked fine when they were rolling out of the factory and would account for why the unplanned patterning hasn’t been more universal. Ford also decided to delay the Bronco’s color-matched roof option until late 2022, citing supply troubles. Those metal-topped SUVs probably won’t see daylight until 2023, leaving customers with the soft top (which can have a kit added to allow the metal hardtop to be installed later) or the molded hardtop that might have some quality control issues.

Ford tapped German supplier Webasto for the part, which required the completion of Webasto Roof Systems Inc. in Plymouth, Michigan, on a fairly tight timeline that wasn’t made any easier by COVID lockdowns. Its first batch may have been subject to some growing pains as it fine-tuned the assembly process or (potentially) rushed to meet order demands. But we’re just guessing here. Ford could have just as easily given them the wrong specifications and then just shrugged when they arrived all sigogglin.

What’s certain is that we’ve heard murmurings that some of the molded hardtops weren’t looking so good after about a month of use. A few customers have also bemoaned the fit and finish, citing misaligned edges, minor warping, and separation from the headliner. Whether those turn out to be isolated issues or something more pervasive, Ford has at least indicated that it’s happy to fix whatever problems arise — provided they’re under warranty.

Meanwhile, everyone’s going to be watching out to see how many more reports of wonky roofs come in to see if it was just the first batch that has problems. If not, Ford could find itself involved in another recall campaign that could have been avoided if a bit more time was taken to make better decisions in preproduction.

[Image: Ford Motor Co.]

Matt Posky
Matt Posky

A staunch consumer advocate tracking industry trends and regulation. Before joining TTAC, Matt spent a decade working for marketing and research firms based in NYC. Clients included several of the world’s largest automakers, global tire brands, and aftermarket part suppliers. Dissatisfied with the corporate world and resentful of having to wear suits everyday, he pivoted to writing about cars. Since then, that man has become an ardent supporter of the right-to-repair movement, been interviewed on the auto industry by national radio broadcasts, driven more rental cars than anyone ever should, participated in amateur rallying events, and received the requisite minimum training as sanctioned by the SCCA. Handy with a wrench, Matt grew up surrounded by Detroit auto workers and managed to get a pizza delivery job before he was legally eligible. He later found himself driving box trucks through Manhattan, guaranteeing future sympathy for actual truckers. He continues to conduct research pertaining to the automotive sector as an independent contractor and has since moved back to his native Michigan, closer to where the cars are born. A contrarian, Matt claims to prefer understeer — stating that front and all-wheel drive vehicles cater best to his driving style.

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  • Flipper35 Flipper35 on Jul 21, 2021

    From the article: Problems include the headliner separating from the roof panels and some discoloration at the seams. Can we do a go-fund-me to get one for Corey?

  • Qbranch Qbranch on Jul 21, 2021

    It's not an issue! It's a feature... after all "they all do that" Just ask ask any sales associate ;) Now, aren't you glad you waited so long and paid over list!? Or look at it another way. In 20 years these "defective" versions will bring another $10k at BAT

    • SCE to AUX SCE to AUX on Jul 21, 2021

      "In 20 years these “defective” versions will bring another $10k at BAT" Ha! Like an upside-down stamp print or something.

  • Analoggrotto I am sick and tired of every little Hyundai Kia Genesis flaw being blown out of proportion. Why doesn't TTAC talk about the Tundra iForce Max problems, Toyota V35A engine problems or the Lexus 500H Hybrid problems? Here's why: education. Most of America is illiterate, as are the people who bash Hyundai Kia Genesis. Surveys conducted by credible sources have observed a high concentration of Hyundai Kia Genesis models at elite ivy league universities, you know those places where students earn degrees which earn more than $100K per year? Get with the program TTAC.
  • Analoggrotto NoooooooO!
  • Ted “the model is going to be almost 4 inches longer and 2 inches wider than its predecessor”Size matters. In this case there is 6” too much.
  • JMII Despite our past experience with Volvo my wife wants an EX30 badly. Small, upscale, minimalist EV hatch is basically her perfect vehicle.
  • Dukeisduke Is the Volvo EX30 even on sale yet? It was pulled from the NACTOY awards because they were having software problems with the vehicle.
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