Summary

Some 2021-2022 Bronco vehicles equipped with 5 doors and a hard top roof may experience a squeak and/or chirp noise from the rear of the vehicle while driving over bumps with the roof installed. This may be due to an insufficient gap between the hard top and the body rear quarter panel. To correct the condition, follow the Service Procedure to adjust this gap to the correct specifications.

Model:

Ford

2021-2022 Bronco
5 door
Hard top roof

Issue: Some 2021-2022 Bronco vehicles equipped with 5 doors and a hard top roof may experience a squeak and/or chirp noise from the rear of the vehicle while driving over bumps with the roof installed. This may be due to an insufficient gap between the hard top and the body rear quarter panel. To correct the condition, follow the Service Procedure to adjust this gap to the correct specifications.

Action: Follow the Service Procedure steps to correct the condition on vehicles that meet all of the following criteria:

2021-2022 Bronco
5 doors
Hard top roof
Squeak and/or chirp noise from rear while driving over bumps with the roof installed

Service Procedure

NOTE: The right rear quarter panel repair procedure is shown; the left rear quarter panel repair procedure is the same.

1. Insert a 3/64 in. (1 mm) plastic feeler gauge in the gap between the bottom/rear corner of the hard top and the rear quarter panel until the gauge is 2 in. (50 mm) deep. (Figure 1)

Figure 1

2. Is resistance felt when trying to insert the feeler gauge?

(1). Yes – proceed to Step 3.

(2). No – this article does not apply.

3. Open the rear door to the fully open position.

4. Position the liftglass assembly in the fully raised position.

5. Remove the 4 pushpins securing the tailgate hinge cover. (Figure 2)

Figure 2

6. Remove the 2 screws securing the tailgate hinge cover. Tighten to 20 lb-in (2.2 Nm). (Figure 3)

Figure 3

7. Carefully remove the tailgate hinge cover from the vehicle and set it aside.

8. Apply firm forward pressure on the rear quarter panel, just above the rear lamp assembly. (Figure 4, Callout 3)

(1). It may be necessary to reposition the rear door to allow for both firm pressure on the rear quarter panel and achieve access to the fasteners at the same time.

Figure 4

9. While applying pressure on the rear quarter panel, loosen fastener 1 (Figure 4, Callout 1) allowing the rear quarter panel to shift slightly forward. Retighten the fastener before releasing the forward pressure.

10. Use a plastic feeler gauge to measure the gap between the bottom/rear corner of the hard top and the rear quarter panel. (Figure 1)

11. Does the gap measure between 3/32 – 7/32 in (2.5 – 5.5 mm)?

(1). Yes – tighten fastener 1 (Figure 4 Callout 1) to 80 lb-in (9.0 Nm) then reinstall the tailgate hinge cover by reversing Steps 5-7. Repair is complete.

(2). No – proceed to Step 12.

12. Apply and hold firm forward pressure on the rear quarter panel, just above the rear lamp assembly. (Figure 4, Callout 3)

13. While applying pressure on the rear quarter panel, loosen fastener 2 (Figure 4, Callout 2) allowing the rear quarter panel to shift slightly forward. Retighten fastener 2 before releasing the forward pressure.

14. Use a plastic feeler gauge to measure the gap between the bottom/rear corner of the hard top and the rear quarter panel. (Figure 1)

15. Does the gap measure between 3/32 – 7/32 in (2.5 – 5.5 mm)?

(1). Yes – tighten fasteners 1 and 2 (Figure 4, Callouts 1 and 2) to 80 lb. in (9.0 Nm) then reinstall the tailgate hinge cover by reversing Steps 5-7. Repair is complete.

(2). No – perform Steps 8-15 until the gap meets the specifications.

2 Affected Products

Vehicle