Windshield Cowl Gap

[Icetek]

I never noticed this before, but today I was doing a deep clean of the windshield and hood when I noticed it.

I don’t have any other Broncos over here in Portugal to compare it with.

Is this huge gap in the middle normal?

It’s tight on both sides, but there’s maybe a 3/4" gap in the middle.

Thanks,
Mike

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[murrman]

It's a known issue. Some have had luck getting it replaced under warranty. I was not so lucky with my local dealer. I may eventually try with another dealer, but I haven't yet. There are a few threads about it here.

 

[CalvinT]

It's tricky getting the cowl in properly. Do it wrong and you'll have a gap. You need to pop all the tabs where the cowl snaps in behind the firewall. Then you can snap the cowl under the windshield. Then snap the tabs in behind the firewall.

 

[totaljustice]

I had the gap as well but my dealer replaced the cowl for me under warranty. No gap appeared since at almost 2 years into ownership.

 

[Lambhair McDaniel]

I have the same. Is this just a superficial issue or could it cause problems? I have wrestled with raising it for warranty work because I am not sure it is important.

 

[CalvinT]

I have the same. Is this just a superficial issue or could it cause problems? I have wrestled with raising it for warranty work because I am not sure it is important.

I would.

The gap will accumulate junk over time, you don't know what problems that willl cause.

 

[Icetek]

It's tricky getting the cowl in properly. Do it wrong and you'll have a gap. You need to pop all the tabs where the cowl snaps in behind the firewall. Then you can snap the cowl under the windshield. Then snap the tabs in behind the firewall.

Thanks for the pdf... strange design with the colors to the right with no text on them but the procedure looks clear enough.

 

[Icetek]

Thanks for the replies. Good to know it is not normal.

I've only been to 1 of 2 local dealers here - the only one that would look at the truck. They did the initial service but only fluids and filters not any software or anything. So not sure what their approach to this under warranty might be.

I might wait for a cooler day and try it myself.

Like CalvinT said it will be a collection point for trash and debris over time. So would prefer to get it fixed.

 

[shaw]

I never noticed this before, but today I was doing a deep clean of the windshield and hood when I noticed it.

I don’t have any other Broncos over here in Portugal to compare it with.

Is this huge gap in the middle normal?

It’s tight on both sides, but there’s maybe a 3/4" gap in the middle.

Thanks,

That’s more gap than I’d consider normal. These old Broncos can have some variation, but if it’s tight at both ends and opens up to around 3/4" in the center, I’d suspect the hood or cowl alignment before assuming it’s supposed to be that way. I’d check that the hood is sitting square and that the hinges/mounts aren’t pulling it up in the middle. Also check the windshield frame and body mounts since a little body movement can change that gap quite a bit.

I’d get some measurements from side to side first before adjusting anything. No need to start chasing it until you know which part is actually out of alignment.

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