UPDATE: Hardtops need to be redesigned! Cracking and bubbling on my second hardtop replacement

[Tricky Mike]

I don’t get it. My 23 has no issues with the honeycombing or anything. Of course it’s always been parked in garage, which I think should be the case with any such vehicle. Do most of you having this issue park outside or drive your broncos in very cold climates where the top sees a lot of expansion and contraction?

It's very strange. My 21 has never spent a day under cover and the top is still flawless. It was a dirt mountain replacement top though, those must have been lovingly handcrafted by artisans.

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[J-Lugster]

It's very strange. My 21 has never spent a day under cover and the top is still flawless. It was a dirt mountain replacement top though, those must have been lovingly handcrafted by artisans.

I think it boils down to a lack of quality control at the Webasto factory because babying your Bronco or treating it like stole it does not seem to impact the failures of the hardtops.

 

[23OBX2.7]

Didn’t understand either - until my 23 cracked in February. Always garaged, Colorado had no winter this year. Ford wouldn’t replace the rear cap (not enough honeycombing) and I only have 3k left on my 3/36, so I got the front panel replacements and drove straight from the dealer to Line-X.

Just encourage the "normal" defect area with dropped sandbags or other blemish free impact area and go back or to different dealer.

 

[Victorsen]

There is a class action lawsuit that this law firm is looking for participants. May be something to look into for those with denied warranty claims.

https://classlawdc.com/2025/07/03/2...king-cracked-roof-class-action-investigation/

 

[Bronco21Maybe]

There is a class action lawsuit that this law firm is looking for participants. May be something to look into for those with denied warranty claims.

https://classlawdc.com/2025/07/03/2...king-cracked-roof-class-action-investigation/

Hope they have better luck than the people that tried to get Ford to take responsibility for their panoramic roofs in the F150s.

 

[Eldowerks]

I only have 3k left on my 3/36, so I got the front panel replacements and drove straight from the dealer to Line-X.

Pics and a write-up would be great!

 

[Victorsen]

There is also a full recall on some.

Ford is recalling 16,200 2021–2022 Ford Broncos (3-door and 5-door models) with molded-in-color hardtop roof panels. These improperly manufactured panels can crack, delaminate, and detach while driving. Owner notifications are underway, but complete replacement parts are not expected to be ready until November 2026

 

[RlsTheBracken]

Pics and a write-up would be great!

Sorry - been traveling and haven’t gotten to this yet. I’ll do a write-up and pics this weekend!

 

[RlsTheBracken]

@Eldowerks finally doing the write-up and pics…

Read the forums about cracked roofs, some on their third or fourth roof, and was glad I didn’t have it - until discovering cracks and warping drying my roof in February. Brought it to the dealer immediately, since I had 33k and I’m coming up on 3 years, as well.The issue seems to be luck of the draw on manufacturing; mine’s more of a pavement princess, though I off-road several times/year. It’s garaged.

Dealer’s really solid, but said Ford would only replace the front and center panels now - though I had honeycombing on the back. They said replacement roof is up to $10k; no thanks. As soon as they installed the replacement panels I drove to Line-X. I went with Premium for the UV protection; owner has been with Line-X 24 years and doesn’t recommend Ultra - doesn’t even carry it. It was about 4 hours and just under $1k out the door (taxes kill ya.)

I really like the roof. It added some weight (dunno how much; it’s not terrible, but the center panel is definitely more awkward. I think the Bronco’s quieter too, but not certain. Glossier than I expected, but not obnoxious. I see it as peace of mind; didn’t want the rear cap to fail right after warranty expired.

 

[Nibroc99]

For the center panel, I definitely can recommend the EZ4x4 rear roof rack. It holds the center panel using the factory clamps and turn-switch-things. Makes removal super easy and is especially worth it if you have a roof lift to remove the rear section.

 

[DALOLA]

@Eldowerks finally doing the write-up and pics…

Read the forums about cracked roofs, some on their third or fourth roof, and was glad I didn’t have it - until discovering cracks and warping drying my roof in February. Brought it to the dealer immediately, since I had 33k and I’m coming up on 3 years, as well.The issue seems to be luck of the draw on manufacturing; mine’s more of a pavement princess, though I off-road several times/year. It’s garaged.

Dealer’s really solid, but said Ford would only replace the front and center panels now - though I had honeycombing on the back. They said replacement roof is up to $10k; no thanks. As soon as they installed the replacement panels I drove to Line-X. I went with Premium for the UV protection; owner has been with Line-X 24 years and doesn’t recommend Ultra - doesn’t even carry it. It was about 4 hours and just under $1k out the door (taxes kill ya.)

I really like the roof. It added some weight (dunno how much; it’s not terrible, but the center panel is definitely more awkward. I think the Bronco’s quieter too, but not certain. Glossier than I expected, but not obnoxious. I see it as peace of mind; didn’t want the rear cap to fail right after warranty expired.

Looks great! I like the black satin finish. This will be my course of action if my top ever starts cracking.

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