First new Ford...Probably the last Ford

[Area51BS]

Understandable. But, just because the issue hasn't happened to you doesn't mean the problem doesn't exist. There are many threads on the window pop-out topic. Tolerances, incoming materials, set up differences, quality checks, differences in operators/inspectors, etc all can lead to a short term issue that doesn't affect all vehicles.

A certain unnamed manufacturer had to disassemble and scrap a bizarre number of partially-built vehicles years ago because one operator was using an unapproved "mold release" that contaminated class-A surfaces. It didn't affect all within the mfg date or VIN range because this operator didn't work every shift. - this is just one example but it's very common.

My guess on the window issue is that whatever gauge/fixture they used for soft top framework got bumped, misaligned, or the operator doing the assembly had one too many coffees (or not enough) that day. You'd be shocked at how easily a disgruntled or constipated operator can muck things up. XD

I agree it is happening. There are some fine adjustments in the soft top lower rear frame I suspect are either too loose or maybe causing window to be too tight. Thereby not engaging front and rear channels properly.

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[ThunderFlash]

I do agree the OP has a legitimate complaint with the way his panels are lining up. Seems excessive. Someone along the way should have second guessed the fit before it ever got delivered to him. You don't need to carry and inspectors stamp to see there are some alignment issues there. But also keep in mind the Bronco is a body on frame design that is bolted together. It is a pretty rudimentary way of building cars, but that is one of the compromises made in building a rugged truck in mass. I believe the OP is comparing his Bronco to unibody designs he has owned in the past that are precision welded by robots. It's a very different architecture and manufacturing approach that is going to result in a better fitting, lighter, likely more stiff, and probably more squeak and rattle free vehicle. A three or four piece easily removable roof is not going to help any of those things, either.

I love my Bronco even more because of its core basic design. Its a little rough around the edges, but it's got the guts where it needs it and for its intended purpose. When I met my wife, she asked me what I did as an engineer and I did not have a simple answer for her. It bugged me for years, but later the perfect description came to me, engineering = compromise management. Most designs start with a target cost that immediately reduces all the possibilities in the world down to a very small box to work within. If engineering has no cost targets, you end up with Formula 1 cars having a 1/4 million dollar steering wheel! Few things in design come with all upside. There are always trade offs in cost, weight, aesthetics, strength, producibility, or something. I personally believe Ford did a very good job of delivering the promised package to market at a "reasonable" price....maybe with the exception of the MIC tops! Mine has been fine so far, but clearly there are some fundamental issues in that design.

 

[rgraphic]

Here is the gap on my drivers side. as seen from the inside as well. I dont get how this should be expected on any vehicle. And yeah I did look over the vehicle, and yeah maybe I should have asked for 2 hours to check over every detail but I did have some degree of faith in the qc from factory I guess as I haven't dealt with issues like these in the past. I will be having the dealer take a look at in the near future. But as others have stated sometimes the dealerships messing with it makes it worse. I currently haven't noticed a water leakage.

 

[ThunderFlash]

Here is the gap on my drivers side. as seen from the inside as well.

I think your missing a seal there.

 

[ThunderFlash]

I think this is the angle you're picture is at, no? I think there is a missing trim or seal piece.

 

[rgraphic]

I think your missing a seal there.

That whole right panel (I believe there are 4 pieces glued together that make up the rear shell) is further out than it should be in just that corner and that notch should be covered by that gasket. It's like the measurement tolerance got screwed up in late 24 models because I'm not the only one. Just the worst case I've seen.

 

[rgraphic]

I think this is the angle you're picture is at, no? I think there is a missing trim or seal piece.

My view is from the back cargo. In the bottom image those two lines should be much closer in length to match the proper alignment of the passenger side. The upper right corner of the shell (I think) is glued together with too big of a gap. Whatever spacer or tool they use when gluing maybe wasn't accurate.

 

[ThunderFlash]

Have you tried loosening the eight bolts on the sides and the two under the top removable panels to see if you can reposition it a little better? The tools are in your Bronco tool kit. The tops are lightweight to be removable, so they are NOT infinitely stiff. It could just be bolted down while being a bit flexed out of shape. Mine sits a little better than yours, but not by a whole bunch. But I see my cap rear side panel looks like it aligns better with the cap rear top panel, too.

 

[rgraphic]

Have you tried loosening the eight bolts on the sides and the two under the top removable panels to see if you can reposition it a little better? The tools are in your Bronco tool kit. The tops are lightweight to be removable, so they are NOT infinitely stiff. It could just be bolted down while being a bit flexed out of shape. Mine sits a little better than yours, but not by a whole bunch. But I see my cap rear side panel looks like it aligns better with the cap rear top panel, too.

I was able to adjust as you and a couple others recommended. I loosened all the bolts to the top, but primarily it was the top two that I was able to shift a fairly good amount once loosened. All bottom bolt locations dont have any room for shifting. to my surprise I was able to make it better. It's about 75% less noticeable now. So I am very happy about that! But... it's because I had to push some of the top out on the already flush passenger side to compensate. So they are both a little off verses way off on one. It's definitely assembled with an improper gap in that top corner on the drivers side and I assume will always be because the shell is glued together at that point(with the spacing off). I was also able to force the gasket a bit higher to just barely cover that hole, though I dont know if it will stay sitting at that hight since its not meant to follow the contours of my corner issue. Here's where it's at now.

 

[rgraphic]

Now that the top is a little less crazy. Can someone help with why this is happening? It's worse than it looks on that receiving side. I haven't got many more door openings before a large piece of the rubber coating is about to rip off.

 

[new to bronco]

Hi had two 2-door broncos, I liked them a lot but they did feel “cheap” one was a base 4 cylinder and the other was a big bend V6. I bought the big bend after selling the base for a small profit and couldn’t stomach the sticker of over $40K so sold it and then picked up a gladiator rubicon sticker of $61K and payed $40K for it and I’m pretty happy with it, the interior has much better materials than the two broncos I had

 

[11811]

Hi had two 2-door broncos, I liked them a lot but they did feel “cheap” one was a base 4 cylinder and the other was a big bend V6. I bought the big bend after selling the base for a small profit and couldn’t stomach the sticker of over $40K so sold it and then picked up a gladiator rubicon sticker of $61K and payed $40K for it and I’m pretty happy with it, the interior has much better materials than the two broncos I had

That's a lot of chrome

 

[#1Broncogirl]

I'm not talking so much about engines or transmissions (though both vws worked flawless). It's mainly body alignment, materials, weatherstripping, paint quality, etc I'm referring to.

I’ve read through your post and wonder have you taken your Bronco back to the dealership while under warranty? Our 21, 2 door had a driver door alignment issue, it hit the front fender when it was hot out. I went to the dealer and they sent me to their body shop which was great. We walked around the entire vehicle for an inspection, they then realigned every panel that was off even a little. I was told all manufacturers have misalignments. Toyota being the best, Chevy and Ford the worst!
Remember the squeaky wheel gets the grease. Maybe we just have a good dealership, they have addressed all my concerns.

 

[jakej]

My 21 has none of these issues, going strong. Maybe you got a Friday before the long weekend build.

Same here. This thread reminds me that I'm so glad that many of us in '21 switched to soft-tops to get our rigs. I've not regretted going with soft-top once. Seems like lots of issues with hard-tops still.

 

[Thiskers]

I love my 22, it was built well. Sure there are probably a few things I could knick knack here and there, but the Bronco is fun as hell to drive and I'd never let tiny things get in my way of enjoying that. My F150 before it went 15 years and 150k miles, only had to take it a mechanic 2 times outside of normal maintenance.

Getting beat up about random stuff feels like a Seinfeld episode. Let go of the tiny things and appreciate the fun things, life gets a lot easier that way.

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