📣 Ford announces MIC hardtop solution (program 21B49): unscheduled orders will get MY2022, delivered & built Broncos will have tops replaced

[dweskamp]

The upside is now those of us moving to MY22 get any potential updates even if its just a color change, but I suspect after the laundry list of Job 1 issues, more stuff will get addressed.

Like the fuzz on the second row seats. That needs to go.

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[Jon1drfl]

Feel free to do what you all will do with this.

 

[Vigor]

I wonder why Ford doesnt just hire Jeep's supplier for hard tops. Problem solved.

They're Fords design

This doesn't sound like just a supplier problem

 

[xmod]

who is making the newly designed tops?

 

[Mrpenn46]

I 100% am hoping the same thing, or a new FJ-style vehicle. Something similar to the Bronco in tech and fun. I had an FJ for 10 years and now own this 4Runner but I'm tired of their weak engines and low tech.

If the 4runner had slightly better power and MPG I'd probably already be in one. It sounds like 23' is the earlies they'll redesign it, and frankly I may trade the Bronco (if I ever get it) in on one depending on where they go on the redesign.

 

[Farrell22]

No. MIC hardtop production for unscheduled First Edition builds will resume late this year with the updated hardtop design. I wouldn't expect this until probably November, as the new tooling still needs to be completed, installed, and tested before production of the new hard tops can begin. Once that happens, they have committed to building new MIC hardtops for all units that have already been delivered, then the "bad batch" Broncos trapped at MAP, THEN for production of new units.

So just to clarify, first roofs being replaced will be already delivered units followed by the trapped “bad builds” at MAP and then lastly the newly produced units which includes the reminder of First Editions? You really think they can get all these rigs with new roofs delivered by December?

 

[Mrpenn46]

who is making the newly designed tops?

My understanding is it's a tooling and process redesign and Webasto is still the supplier.

 

[LowerDixie77]

I don’t want a 4 door or a soft top. Looks like I’ll have to wait it out. May switch to green. I’ll be able to pay cash by the time it’s ready. Probably won’t be spending as much time on Bronco6g. I’ll check in with yall around December.

 

[Vigor]

So just to clarify, first roofs being replaced will be already delivered units followed by the trapped “bad builds” at MAP and then lastly the newly produced units which includes the reminder of First Editions? You really think they can get all these rigs with new roofs delivered by December?

Absolutely not

 

[UtahLars]

I think this is about the best news possible at this point. FE and current VIN's will get their hardtop this year. Soft tops will get theirs, and dealers will get likely get a few stock units.

Well, it doesn’t actually say that FE folks will get their cars/hardtops this year. It says that all FE folks will get a 2021 Bronco. Basically it says, in effect, that the plan is to do all remaining FE production between November 2021 and late December 2021. Based on that it seems almost certain that some FE folks will not be able to take delivery until early 2022.

At least an answer of some kind is a step forward, and I’m sure the folks at Ford regard this as a big decision. But the timetables are very, very tight. Keeping to this schedule wlil be a challenge.

 

[Powers2020]

I have not received an email. Anyone else?

 

[jaruss01]

No. MIC hardtop production for unscheduled First Edition builds will resume late this year with the updated hardtop design. I wouldn't expect this until probably November, as the new tooling still needs to be completed, installed, and tested before production of the new hard tops can begin. Once that happens, they have committed to building new MIC hardtops for all units that have already been delivered, then the "bad batch" Broncos trapped at MAP, THEN for production of new units.

If that ends up being the case, then they have some audacity telling non-FE mic guys sitting on assigned build dates to wait for an update in early October. There's basically zero chance they fulfill even a small percentage of new orders in time for 2021 MY. 2022 production starts in December. It's almost an impossible feat. Let's say there's 2,500 bad batches, plus what, 5-6,000 unbuilt FEs (not double counting some FEs in the bad batch), plus fixing recalled hardtop (but may be limited to low hundreds)...in THE month of November, plus potentially promising to build assigned VINs....am I missing something @PREMiERdrum

 

[702_SR5]

This is just surreal.

And this hardtop fiasco can't be blamed on Covid. This is poor management that allowed a clearly deficient design and manufacturing process to go forward.

Glad I was recently able to trade in my 4Runner for a new one. (There are none on dealer lots, so I basically bought it while it was still on its way from Japan). It will tide me over a few years while Ford gets their **** together.

Hopefully Ford does, because after all the problems I had with my Rubicon, I don't want to go back to a Jeep though I miss its capabilities.

 

[Destroyer]

That makes sense, although I know lots of folks in body/mechanic field around me and the majority I wouldn't trust.

You and I both. Although the task of pulling and re-installing glass isn't a particularly hard job, I don't trust a dealer mechanic to do such a job. Now if someone who's whole business is removing/replacing glass on cars...yeah, let them do it. No way I'm trusting a mechanic at a dealership to do anything beyond changing my oil...and even that is questionable. Too many bad previous experiences. I feel bad for those who have a bronco, have a MIC, and now need to worry about this like yourself

 

[#Hopinandfindout]

Updated by Administrator with full FAQ and Customer Satisfaction Program info.

Full Order Holder FAQ:

Awareness Communication - Upcoming Customer Satisfaction Program 21B49
(Certain 2021 Model Year Bronco Equipped with a Hard Top Roof Roof Panel Delamination)

Some extra info from @PREMiERdrum



All new tooling and an altered design. It became quite clear that even when manufactured exactly to spec that the design was flawed.

The timeline here is optimistic, but the right move nonetheless.


No. MIC hardtop production for unscheduled First Edition builds will resume late this year with the updated hardtop design. I wouldn't expect this until probably November, as the new tooling still needs to be completed, installed, and tested before production of the new hard tops can begin. Once that happens, they have committed to building new MIC hardtops for all units that have already been delivered, then the "bad batch" Broncos trapped at MAP, THEN for production of new units.



Hey, you have every right to be a dick. This has been a mess.

The design issue is the unfinished edges. Initially, these were to be treated and sealed but it was never successful. The "coating" applied at the plant lasted for about a week, if that. The other issues plaguing the MIC top - thickness of outer ply, uniformity of material thickness, and forming issues within the clamshell - were perhaps made more challenging by the tooling but not necessarily impossible. This new design and tooling should aid in ALL these factors.

As for the 8/2 "full speed" production, that was the plan. Heels were firmly dug in on the engineering of the top and all fingers were pointed towards Plymouth. There was hope that the "best" of the roof units being delivered to MAP could at least be used to complete FE and stranded builds, but as more and more units were evaluated, it became clear that it was a bigger liability to release more of these out into the wild than to just scrap the thing and start over.

Like I said last night, this move HURTS... especially the "bad batch" crew of 2,200+ builds stuck at MAP, but it's absolutely the best way to address it at this juncture. A LOT of these headaches could have been alleviated by pulling the plug when the first issues became apparent, but that's not where we are.



- A few hundred.

- Yes.



The design will look very much the same (and be the same color, to those of you asking). Main points to address in the update:

- Rolled /finished edges where there were formerly raw cuts.
- Thicker, more uniform outer layer of material.
- Improved injection process to fix forming issues in the clamshell.

Also, I've seen several people asking why they can't just get their truck now with a bad roof and replace it later. Two huge problems will prevent that from happening:
- Ford doesn't want any more "bad" units running around beyond the few hundred already out there.
- They want no part of shipping any more of these things than they already have to. Freight is going be enormous on them and there is a substantial risk of damage while shipping. I doubt they have a packaging and logistics plan for them but I can imagine it's going to be incredibly costly.



No - the entire roof assembly is being replaced. This is being described this way as they won't ship the "replacement kits" to the dealers with the glass in place. It will need to be installed in the new cap by the dealer.


Note:

Lots of people are assuming this means a new supplier, but I don't have any confirmation of that. Update from @Nickp , the following is correct: From what I can tell, this new tooling for the MIC hardtops is being designed and paid for by Ford and will be installed at the Plymouth plant for Webasto to produce.

The MOD tops coming in 23 are from a new supplier that has yet to be publicly identified.

Further info from @Nickp: My contact at Ford reached out, and basically summed it up that they need to make sure that these things are ready for the adventures that we are going to put them through. The current hardtop and the quality offered just don't reach that standard, so they are just putting the kibosh on any more going into circulation before they fix the root of the problem. As outlined above, the fewer hard tops they have to ship around the country the better. When the new tops are being built, they are going to FiFo the current sitting orders. Basically, the ones that were built first will be the first to get tops and get sent on out to their final destination. While the ones that are currently built are being sent on their way, the goal will be to get people with a hardtop Bronco in their possession already the new top, along with finishing up the first editions and already scheduled builds. It's not ideal, but this is "THE" solution that will be the only thing to fully fix things.

UGH!!! my concern is not that they are fixing issues they have found, nor is it that the builds of 2021 Models are delayed, nor is that we reserved our build date in July of 2020, nor is that the dealers know nothing about any of what is going on, my biggest concern is FORD is not sending this communication out to everyone who has a reservation or order placed. Why is it so hard to send out communications to your customers? im in a similar business.. (Trailer manufacturing) we have many of the same issues and we are regularly calling our dealers, and customers to give parts updates, quality updates, and delivery updates. CALLING them.. yes we sell more trailers in a year than 125, 000 (Bronco orders from reservations) its frustrating to me as it seems like it is a big secret and customers have to go search the WEB to get answers to the delay questions.. My dealer knows less than me and I search the web daily.. signing off till 2022.. ;-(

 

[mandyhoth]

Again, I believe this is social media driven. Can't risk a bunch of people posting pictures with hashtag #leakybronco. That's the biggest exposure because they can't control it so they are taking it off the board first.

There should be a separate apologist forum, BTW. It's complicated, it's a pandemic, manufacturing is hard. That stuff is priced in. I build and manufacture things. Nobody is grading me on a curve because the world is more unpredictable. I can promise that there is a lot of 'how did we let this happen' discussion going on in Michigan right now. it's a pandemic, and supply chain is F'ed. You don't get extra credit for managing that because you made commitments and nobody cut a check for your best effort to deliver their Bronco. They wanted a Bronco.

If you had put out a disclaimer that due to the pandemic, supply chain is stressed and that anybody thinking about a Bronco should consider the fact that they could be facing a 90-120 day delay, then sure, buyer beware. You didn't do that because it would have impacted sales.

I’m sure that is the reason, but in my opinion I think the 2k+ Broncos parked on the lot will get more bad press than the few that have been delivered with #leakyroof Especially where the general public will know Ford is addressing the problem and they are being sent new improved tops as the #leakyroof becomes more prevalent. I think Ford pretty much put that fire out on all the delivered ones

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