NHTSA Complaint #11676532 — 2021 FORD BRONCO

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.