Hardtop cracks? Something else?

[Dadsquatch]

When my first top started to get the cracks by the window, I wanted to just leave it. But then after a car wash, I saw a water droplet start squeezing it's way out of the crack, and that is what made my decision to put in a warranty request and get a new top. I'm now on my 4th top. EVERY top has something wrong with it one way or another.

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[Dadsquatch]

Lighting and angle is key. Here is my hard top in different lighting and angles. And this is just to show the delaminating. Not cracks.

 

[Min_Ahn]

Got a picture of the hail/dent/divots?

And can you get a picture of the area under the window toward the front, parallel to the inner bolt, shining an led light, multiple angles? Not trying to add fuel to the fire, but it took me awhile to get the right angle and it was only becuse one day the sun was hitting it as it came through the garage door and I was working at the bench.

I can take a picture of mine and it will look totally normal. I can even walk by it in full sunlight and not see anything at all.

It "looks like" it's been caught in a hail storm but it never did. I've attached the photo in the previous post.

 

[1986Bronco]

Did it always look like that or did it get worse over time?

 

[a.smith]

Add me to the list of brand new '23 hard tops with cracks at the bottom rear window area. They are barely visible so far. I'm interested to see how this is handled over time. Not too worried yet as I have a couple more years for Ford to get the manufacturing right before I warranty it.

 

[Dude1967]

When my first top started to get the cracks by the window, I wanted to just leave it. But then after a car wash, I saw a water droplet start squeezing it's way out of the crack, and that is what made my decision to put in a warranty request and get a new top. I'm now on my 4th top. EVERY top has something wrong with it one way or another.

Same issue here. I still to this day do not understand Fords thinking on this. Cutting costs is going to bite them big down the road. Period.

 

[1986Bronco]

Ford reached out today via phone and let me know they are closing the case.

It is in the hands of the dealerships and it does not matter that they have pictures of mine and of the others.

They said that I could call and reopen the case after the dealership has the vehicle for whatever amount of time they deem necessary.

They were adamant that this is a corrosion issue and they wanted the dealership to eliminate me as the issue.

I suppose it was me that damaged every other one that I saw in that same day?

 

[1986Bronco]

2 Broncos in our parking lot. Using a flashlight, both have cracks in the same spot. Was only able to get a picture of 1. Walking around a parking lot with a flashlight up to random vehicle windows will get a person around here shot.

It absolutely takes a flashlight and the right angle to see in the daylight.

Still at 100 percent failure rate.

 

[1986Bronco]

I was wrong. There are 9 more Broncos on this first lot...

Still 100%.

Pictures on the way.

 

[1986Bronco]

Also.

As an engineer...I'm an idiot.

A large portion of these are still wrapped in plastic on the inside and have never been "on the road" but still have the "cracks".

This has got to be an installation error at the factory or a storing at the warehouse problem. Maybe even a mass shipping problem. I am leaning towards installation/factory line for several reasons.

These are possibly stress cracks IN the material that, after they are formed, work their way to the surface over time with more driving and road vibrations, etc.

Edit: I have also been running through mental plausible scenarios like heat migration from the glass to the top, the temperature of the glass sealer, the chemical composition of the glass sealer interacting with the MIC material (hey Ford, you are so worried about US putting the wrong chemicals on the hartdop...are you worrried about yourself?) , etc. At this point, I might be spending more mental power on this than FORD.

Ford. Where are you at? We are solving problems for you...

 

[1986Bronco]

Today.

Only because I got worked in this morning at service. And they did not keep the vehicle.

Kudos to them for working with me.

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[userdude]

Ford. Where are you at? We are solving problems for you...

Technical difficulties, please stand by.

To wit, if I got a roof replacement (I don't think I need one...?), I'd sell it and go Armadillo IF they can actually produce their tops. Seems a big IF but I stay optimistic! lol

 

[1986Bronco]

Technical difficulties, please stand by.

To wit, if I got a roof replacement (I don't think I need one...?), I'd sell it and go Armadillo IF they can actually produce their tops. Seems a big IF but I stay optimistic! lol

I do not think a replacement is necessary until it breaks the outer layer. As of now, I stand by the idea that these are stress cracks IN the material. I have seen plenty of stress cracks in thermoplastic, thermoplastic resin, thermoplastic infused carbon fiber, etc. on high use [items] that continue to function with no issue (although their routine checks were increased and markers were placed to identify if the cracks were spreading, etc.) I somewhat akin this to cracks in concrete. Is it possible to use a different material that will not crack... yes. But we still use concrete. And none of that self-healing Roman-era stuff. Just straight up concrete that will crack. And then we monitor it.

If the core was not a fiber based material I would probably walk away at this point.

The problem, as I see it, is that once the crack(s) breaks through the outer layer, moisture intrusion becomes an issue and may break down the fibrous inner material. If that inner matieral was moisture resistent AND there were weep holes in places for gravity draining...we would more than likely be fine.

 

[1986Bronco]

And I apologize for the jumble of pictures. It was difficult with the salesmen on the lot, holding a mug of coffee, and trying to beat the rising sun. These Broncos may not have been there before and were possibly delivered during the week, I am not sure how I missed them. If any pictures are missing, let me be clear that it was still a 100% failure rate with a mix of 2 and 4-door Broncos. This time, all on the new lot. I have full pictures of each but am keeping the dealership name out of it.

And Ford, you are welcome. An elderly gentleman and his wife in a newer Ranger stopped me becuase they thought I was a salesperson. I walked next to them as they drove back up to the front and brought a salesperson to them.

 

[1986Bronco]

Dealership called and said that the warranty claim was officially denied.

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