The Water Leak Saga Continues...

Marmot

Dec 31, 2022

This update is more as a reference for others in case someone else experiences the same issue and is looking for more information.

I have had quite a large leak on the front passenger side of the Bronco when it rains (has not had heavy snow sit on it [yet]). The first time, I found quite a large puddle on the passenger side floor. Water was coming into the vehicle from the upper airbag compartment (located above the passenger seat) and down the A pillar. It was taken into the shop and a seal replaced. Did not fix the issue, as it was the same situation when it rained again next (this was about 2-weeks ago). Took it in a second time and there was much more done to remedy (replaced all seals, glue, sealer, strip calk in body seams, header seal). It rained again the last 2 nights and unfortunately the issue persists...

This time when going out to assess the leak I noticed nothing was coming in from the airbag compartment, just in from down the A pillar. However, I noticed a little moisture at the seam of the upper airbag compartment so I pushed on it. Water came pouring out.

I did notice there are quite a lot of other complaints related to this issue and a service bulletin (SB) had been issued (SB 21-2403). The main cause tied to this SB are excess body gaps that require additional sealant to fill in the space (see figure 8 from SB below).

In addition to going to trying to work this issue out with the dealer I have two (2) case numbers with Ford, but those have not gone anywhere. I just get case numbers. From there it's radio silence, but I also understand there isn't much they can do but send me to a dealer.

I really, really love this vehicle. The quality issues Ford is facing is unfortunate. I am going to work with my dealer on round three to try to get this resolved. If it fails again, I don't know...

Figure 8 from SB 21-2403

Laura, BuckYeah

Last edited by a moderator: Dec 31, 2022

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Dec 31, 2022

So sorry to hear you are having issues. It would have to be frustrating.
Hopefully 3 times a charm and it gets fixed correctly.

2022 Bronco Badlands, 4D, Hot Pepper Red, 2.7, Squatch, Lux, and MIC.
7/13/2020 10:04pm reservation. Blend 6/16/2022 Delivered 6/26/2022.
Dealership - Stephen's Auto Center.

Laura, BuckYeah

Dec 31, 2022

Marmot
This update is more as a reference for others in case someone else experiences the same issue and is looking for more information.

I have had quite a large leak on the front passenger side of the Bronco when it rains (has not had heavy snow sit on it [yet]). The first time, I found quite a large puddle on the passenger side floor. Water was coming into the vehicle from the upper airbag compartment (located above the passenger seat) and down the A pillar. It was taken into the shop and a seal replaced. Did not fix the issue, as it was the same situation when it rained again next (this was about 2-weeks ago). Took it in a second time and there was much more done to remedy (replaced all seals, glue, sealer, strip calk in body seams, header seal). It rained again the last 2 nights and unfortunately the issue persists...

This time when going out to assess the leak I noticed nothing was coming in from the airbag compartment, just in from down the A pillar. However, I noticed a little moisture at the seam of the upper airbag compartment so I pushed on it. Water came pouring out.

I did notice there are quite a lot of other complaints related to this issue and a service bulletin (SB) had been issued (SB 21-2403). The main cause tied to this SB are excess body gaps that require additional sealant to fill in the space (see figure 8 from SB below).

In addition to going to trying to work this issue out with the dealer I have two (2) case numbers with Ford, but those have not gone anywhere. I just get case numbers. From there it's radio silence, but I also understand there isn't much they can do but send me to a dealer.

I really, really love this vehicle. The quality issues Ford is facing is unfortunate. I am going to work with my dealer on round three to try to get this resolved. If it fails again, I don't know...

Figure 8 from SB 21-2403

I was thinking of your case yesterday after picking up my Bronco from the dealer. It was raining so I thought “this will be the test”. No leaks, but it really wasn’t raining that hard. Good luck to you, I hope they can figure it out once and for all!

2023 Bronco,Black Diamond 🏴‍☠️ Velocity Blue 🟦, 4Door, SAS, MIC, Mid, 2.7m, Orig Order: 9/10/21 Blend Date: 11/30/22. Built: 12/02, Shipped 12/4, Arrived at dealer on 12/23, Took possession on 12/30/22!!! 476 Days after ordering.
Goodyear, AZ 🌵🔆

BuckYeah, Jakob1972

Dec 31, 2022

I had the same issue on my new Bronco Badlands. It was leaking from exactly the same location. I took it back to my Ford Dealer and they said they've had three other Broncos come in with the same issue. Fortunately they fixed mine in a couple of hours and my vehicle has been in a few down pours since with no issues. I asked the maintenance rep what they did to correct the problem and he said all they had to do was readjust the hard top for a proper alignment. Good luck with your Bronco! They are awesome vehicles!

Laura, BuckYeah

Jan 01, 2023

BroncoFred
I was thinking of your case yesterday after picking up my Bronco from the dealer. It was raining so I thought “this will be the test”. No leaks, but it really wasn’t raining that hard. Good luck to you, I hope they can figure it out once and for all!

Glad yours is good! It seems the majority have no issues, but I am sure Ford will resolve this for the '23 models given the SB and the number of complaints issued.

BuckYeah

Jan 01, 2023

Jumpmasterken27
I had the same issue on my new Bronco Badlands. It was leaking from exactly the same location. I took it back to my Ford Dealer and they said they've had three other Broncos come in with the same issue. Fortunately they fixed mine in a couple of hours and my vehicle has been in a few down pours since with no issues. I asked the maintenance rep what they did to correct the problem and he said all they had to do was readjust the hard top for a proper alignment. Good luck with your Bronco! They are awesome vehicles!

Glad it was an easy fix. After reading this I went ahead and removed the entire roof and re-installed just in case. Can't hurt. Overall, I am confident we will get the issue resolved. Just a bit frustrating. Outside of this issue the Bronco has been absolutely amazing. Awesome machines indeed!

Laura, Jumpmasterken27

Jan 01, 2023

Deano Bronc
So sorry to hear you are having issues. It would have to be frustrating.
Hopefully 3 times a charm and it gets fixed correctly.

We'll get it resolved eventually, I'm sure. Just want to get it resolved before we get any major snowstorms (keeping it parked outside for now).

Laura, BuckYeah

Jan 01, 2023

I think with both the HT and the ST we will have to be diligent in keeping the gaskets lubricated with silicone to prolong the life of the seals.

BuckYeah, BroncoFred

Jan 02, 2023

TK1215
I think with both the HT and the ST we will have to be diligent in keeping the gaskets lubricated with silicone to prolong the life of the seals.

Hmm with the roof rack I will not be able to remove the rear roof as often as those without the rack, so I will not be able to be as diligent with the silly cone. So I wonder if this will cause issues. I know everyone situation will be different.

Bronco Nation 1100. Everglades, Desert Sand
Res: 7/30/20 ordered 1/22/21 reorder 10/15/21 changed to Everglades 3/9/22 schedule 8/29/22 bumped to 9/5; 9/7/22 blend, 9/9 Mods, 9/26/22 completed, 10/7 shipped, 11/3/22 delivery

BroncoFred, BuckYeah

Jan 02, 2023

It's unfortunate that you're experiencing this as a new owner. I hope they rectify the situation soon and to your complete satisfaction. What's interesting is that these vehicles have a history of water intrusion. I recall reading something about the first-generation Broncos having drainage issues, and the solutions were pretty simple. Let's hope that's the case with yours!

Chris here. I drive a 2-door Velocity Blue 2023 Ford Bronco Badlands with Sasquatch, Lux, a 2.7L V6, and an automatic transmission. It’s fun.

"Stupidity is a more dangerous enemy of the good than malice." - Dietrich Bonhoeffer

Laura, Marmot

Jan 02, 2023

#10

Jakob1972
Hmm with the roof rack I will not be able to remove the rear roof as often as those without the rack, so I will not be able to be as diligent with the silly cone. So I wonder if this will cause issues. I know everyone situation will be different.

I thought about that also and from what I’ve seen, I believe most issues are with how the front panels seal. Two pieces instead of one. Again that doesn’t address the leak on the A pillar, but I am just thinking long term. I guess it depends on what racks people are running and accessibility.

Jakob1972, BroncoFred

Jan 04, 2023

#11

Jumpmasterken27
I had the same issue on my new Bronco Badlands. It was leaking from exactly the same location. I took it back to my Ford Dealer and they said they've had three other Broncos come in with the same issue. Fortunately they fixed mine in a couple of hours and my vehicle has been in a few down pours since with no issues. I asked the maintenance rep what they did to correct the problem and he said all they had to do was readjust the hard top for a proper alignment. Good luck with your Bronco! They are awesome vehicles!

This blows my mind but based on your post I thought I would take the entire hardtop off and re-install it, carefully making sure that all panels were lined up and seated properly...

It has rained twice since doing so (raining as I type this) and not one drop of water to be found inside. If this was part of the issue it had to have been with the rear seat panels, because the front panels had been removed multiple times.

So far so good. Appreciate the feedback!

EGBronc, Jumpmasterken27

Feb 12, 2023

#12

Thought I would provide one more update here for reference. At first, I thought the leak was squared away. There were a couple of rains where the water didn't seem to be getting in but it turned out it was just pooling in the upper support/frame above the passenger seat and airbag compartment. The water gets in past the roof panel, down into the upper crossmember, and goes two directions - it leaks down directly from the airbag compartment onto the floor, and it also runs down the A pillar down onto the door panel and dash (see images below).

As I type this, the Bronco is in the shop for the 4th time. I was able to drive it in as it was raining so they were able to see the water leaking in. This time, however, the Service Manager at my dealer is fully engaged and personally overseeing the project. In addition, Ford has reached out to me and to the dealer and they have escalated the issue to the Ford engineering team, who is having calls and working closely with the dealer to resolve. Both teams were a little stumped at first. As of now, they are replacing the passenger side roof panel and all seals, which is slated to come in on Tuesday.

I will say, both the dealer and Ford have been great, especially my dealer. It's definitely an unfortunate situation, though. I do still love the Bronco and hope this squares the issue away for good.

SuperMike, EvlNvrDys

Feb 12, 2023

#13

My goodness, that’s just awful. Have you started the lemon law process in your state? It would be worth it at this point. Even if they fix the leaking issues, your airbags and probably other components have suffered water damage and may be compromised. It seems like it would be best to compel Ford to buy the vehicle back and get into a new one.

Marmot

Feb 12, 2023

#14

Sulley
My goodness, that’s just awful. Have you started the lemon law process in your state? It would be worth it at this point. Even if they fix the leaking issues, your airbags and probably other components have suffered water damage and may be compromised. It seems like it would be best to compel Ford to buy the vehicle back and get into a new one.

I have reviewed the process here in Ohio but haven't started anything. Being that they are on attempt number 4, it does qualify for refund or replacement. The issue then becomes the wait time of a new Bronco, as I would want a replacement. I have been slightly concerned with internal water damage but not overly. Ford did place a Premium pack 5yr/100k extended warranty on the VIN.

SuperMike, Deano Bronc

Feb 12, 2023

#15

Marmot
I have reviewed the process here in Ohio but haven't started anything. Being that they are on attempt number 4, it does qualify for refund or replacement. The issue then becomes the wait time of a new Bronco, as I would want a replacement. I have been slightly concerned with internal water damage but not overly. Ford did place a Premium 5yr/100k premium extended warranty on the VIN.

You may be able to use it as leverage to get them to replace other affected parts that have been water logged, or to help get into another Bronco faster than you normally would. If that happened to me, I’d be telling them to take this lemon back. Who knows what else may be wrong with it.

Marmot

Feb 12, 2023

#16

Marmot
I have reviewed the process here in Ohio but haven't started anything. Being that they are on attempt number 4, it does qualify for refund or replacement. The issue then becomes the wait time of a new Bronco, as I would want a replacement. I have been slightly concerned with internal water damage but not overly. Ford did place a Premium 5yr/100k premium extended warranty on the VIN.

At least they appear to actually be involved in the process and also gave you the extended warranty.

Griffinftw, Deano Bronc

Feb 12, 2023

#17

TK1215
At least they appear to actually be involved in the process and also gave you the extended warranty.

Agree. I’m willing to see how this attempt goes. It’s “all hands on deck” so I’m confident they will get it resolved. 🤞🏻

Sulley

Feb 12, 2023

#18

My rear window leaks a bit from the top.

"There's nothing better for the inside of a man than the outside of a Bronco" - John Bronco

RoboNC

Feb 19, 2023

#19

Hopefully my last update here. Fourth time I believe is the charm. Ford's engineering team and my dealer have been working diligently to get this resolved and they believe they have it fixed (shout out and thanks to both teams, who have been great, especially my dealer).

On day 2 of this event, Ford mentioned they did find a record in their system that was similar to mine and a replacement hard top panel (front passenger) corrected the issue, so they shipped a new panel to install and test. The day they got the panel my dealer found the leak - about 3.5 inches before the mid panel is where they first noticed the water and they were able to trace it back to the mid panel seal. The water would get in and run down the inside of the roof rail and down through the front passenger side airbag compartment and A pillar and onto the door, dash, and ultimately collect on the floor.

As of yesterday, they have replaced the mid panel seal that runs side-to-side and so far it has passed all of their hose tests. They even borescoped the rail during the test to make sure they couldn't see any moisture getting inside. It is supposed to rain here tomorrow so they asked if they could hang onto it a couple more days for a rain test. If all is successful, which it should be, I should get the Bronco back Tuesday.

It's been a couple weeks since I dropped ol' Saddlebag off. At this point it is starting to feel like I am waiting to take delivery all over again (lol). Look forward to it being back in the driveway. Nice and dry this time.

SuperMike, TK1215

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