22C12 – Windshield Adhesion Repair – 2022 Ford Bronco & Ranger

June 24, 2022 NHTSA CAMPAIGN NUMBER: 22V451000

Inadequate Front Windshield Bonding/FMVSS 212

A windshield that separates from a vehicle during a crash can increase the risk of injury.

 

NHTSA Campaign Number: 22V451

Manufacturer Ford Motor Company

Components VISIBILITY

Potential Number of Units Affected 63,294

 

Summary

Ford Motor Company (Ford) is recalling certain 2022 Bronco and Ranger vehicles. The windshield may not have been properly bonded to the vehicle, which could allow it to detach. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 212, “Windshield Mounting.”

 

Remedy

Dealers will remove and reinstall the windshield, free of charge. Owner notification letters are expected to be mailed July 11, 2022. Owners may contact Ford customer service at 1-866-436-7332. Ford’s number for this recall is 22C12.

 

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.nhtsa.gov.

 

Check if your Vehicle has a Recall

 


2022 Ford Bronco Sport
2022 Ford Bronco Sport

 


AFFECTED VEHICLES

Vehicle Model Year Assembly Plant Build Dates
Bronco 2022 Michigan Assembly December 08, 2021 through April 12, 2022
Ranger December 17, 2021 through April 12, 2022

 

REASON FOR THIS COMPLIANCE RECALL

All of the affected vehicles may not conform to the requirements specified by Federal Motor Vehicle Safety Standard (FMVSS) 212 Windshield Mounting, due to the potential for inadequate urethane adhesion around portions of the glass. An improperly adhered windshield may not stay adequately retained in a crash, which may increase the risk of injury to an occupant. Affected vehicles could experience increased wind noise or water leaks.

 

SERVICE ACTION

Before demonstrating or delivering any new in-stock vehicles involved in this recall, dealers are to remove the windshield and improve the windshield urethane to body adhesion using the attached procedures. This service must be performed on all affected vehicles at no charge to the vehicle owner.

 

OWNER NOTIFICATION AND MAILING SCHEDULE

Owner letters are expected to be mailed the week of July 11, 2022. Dealers should repair any affected vehicles that arrive at their dealerships, whether or not the customer has received a letter.

PLEASE NOTE:

Federal law requires dealers to complete this recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $21,000 per vehicle. Correct all vehicles in your new vehicle inventory before delivery. 

 

SOLD VEHICLES

  • Ford has not issued instructions to stop selling/delivering or driving used vehicles under this compliance recall. Owners should contact their dealer for an appointment to have their vehicles remedied as soon as practicable. Owners can continue to safely drive their vehicles.
  • Immediately contact any of your affected customers whose vehicles are not on your VIN list but are identified in OASIS. Give the customer a copy of the Owner Notification Letter (when available) and schedule a service date.
  • Correct other affected vehicles identified in OASIS which are brought to your dealership.
  • Dealers are to prioritize repairs of customer vehicles over repairs of new and used vehicle inventory.

 

STOCK VEHICLES

  • Correct all affected units in your new vehicle inventory before delivery.
  • Use OASIS to identify any affected vehicles in your used vehicle inventory.

 

DEALER-OPERATED RENTAL VEHICLES

The Fixing America’s Surface Transportation (FAST) Act law effective June 2016 prohibits a rental company from selling, renting or leasing vehicles subject to a safety or compliance recall. Please consult your legal counsel for legal advice.

 

TITLE BRANDED / SALVAGED VEHICLES

Affected title branded and salvaged vehicles are eligible for this recall.  

 

OWNER REFUNDS

  • This safety recall must still be performed, even if the owner has paid for a previous repair. Claiming a refund will not close the recall on the vehicle.
  • Ford Motor Company is offering a refund for owner-paid repairs covered by this recall if the repair was performed prior to the date indicated in the reimbursement plan, which is posted with this bulletin. Owners are directed to seek reimbursement through authorized dealers or, at their option, directly through Ford Motor Company at P.O. Box 6251, Dearborn, MI 481216251.
  • Dealers are also pre-approved to refund owner-paid emergency repairs that were performed away from an authorized servicing dealer after the end date specified in the reimbursement plan. Non-covered repairs, or those judged by Ford to be excessive, will not be reimbursed.
  • Refunds will only be provided for the cost associated with windshield repair due to inadequate urethane adhesion.

 

RENTAL VEHICLES

Dealers are pre-approved for up to 1 day for a rental vehicle. Follow Extended Service Plan (ESP) guidelines for dollar amounts. Rentals will only be reimbursed for the days the vehicle is at the dealership for part replacement. Prior approval for more than 1 rental days is required from the SSSC. Contact the SSSC via the SSSC Web Contact Site for consideration and approval if appropriate.

 

PARTS REQUIREMENTS

Part Number Description Order Quantity Claim Quantity
Consumables Required for all Vehicles
Obtain Locally Masking Tape Claim as MISC OTHER
Glass Cleaner
Dow BETAPRIME 5504G / Sika Primer-207 or equivalent
SikaTack MACH 60 / SikaTack MACH 30 / Dow

BETASEAL Express / Sika Tack ASAP

Urethane Adhesive or equivalent

Roloc Disks or equivalent for urethane removal
Isopropyl Alcohol
Ford Approved Epoxy Based Primer
Related Damage Only – Base Part Numbers
-7803100- Bronco – Windshield As Needed

VIN Specific – Only if breaks during removal procedure.

-2103100- RangerWindshield

 


CERTAIN 2022 MODEL YEAR BRONCO AND RANGER VEHICLES — WINDSHIELD ADHESION REPAIR

 

SERVICE PROCEDURE – BODY SHOP INSTRUCTIONS

BRONCO VEHICLES

NOTE:  These instructions are not intended to be followed from beginning to end. There are several locations where procedures must be completed by other groups before the procedure in these instructions can be resumed.

The instructions should be followed in this order.

1. Body Shop Part One – Prepare vehicle for repairs – Steps 1-2

2. Glass Company Part One – Remove windshield – Separate attachment

3. Body Shop Part Two – Improve flange adhesion – Steps 3-10 as required.

4.  Glass Company Part Two – Install windshield – Separate attachment

5.  Body Shop Part Three – Calibrate Image Processing Module A – Steps 11-13

 

BODY SHOP PART ONE

1. Remove the cowl panel grille. Please follow Workshop Manual (WSM) procedures in Section 501-02.

2. Remove the windshield header trim panel. Please follow WSM procedures in Section 501-05.

 

GLASS COMPANY PART ONE – SEPARATE ATTACHMENT

BODY SHOP PART TWO

3. Cover/protect the body and interior of the vehicle with a one-time use, disposable drop plastic.

4. Using a scraper, cut through the urethane bead vertically down to the painted surface to create a starting point.

– Once reaching the painted surface, pry one side of the bead up with the scraper.

– Using fingers, work to peel the urethane off the windshield body flange.

5.   In areas where the urethane peeled up cleanly:

–  Use 400-600 grit sandpaper or a fine Scotch-Brite pad.

–  Manually scuff the clear coat lightly until it displays a white haze.

– Be sure to only abrade the flange.

–  See Figure 1.

 

6.   In areas where the urethane did not peel up cleanly:

–  Use a Scotch-Brite 3M Roloc disk to remove all remaining urethane from the flange.

– Attempt to minimize abrasion to the painted surface.

– See Figure 2.

 

7. Clean off the entire windshield flange from all dirt and debris.

8. Using Isopropyl Alcohol and a lint-free cloth, clean off the flange surface. Allow one minute for the Isopropyl Alcohol to evaporate.

9. Apply tape to the edges of the windshield flange to protect the surface of the vehicle. See Figure 3.

10. Apply one coat of any Ford approved epoxy based repair primer to any spots where the roloc disk was used to grind off the urethane. See Figure 4.

– Allow time for the primer to dry per the manufacturer’s instructions.

 

GLASS COMPANY PART TWO – SEPARATE ATTACHMENT

BODY SHOP PART THREE

NOTICE: The door windows must be left open during the adhesive curing time.

WARNING: Do not drive vehicle until the urethane adhesive seal has cured. Follow urethane adhesive manufacturer’s curing directions. Inadequate or incorrect curing of the urethane adhesive seal will adversely affect glass retention. Failure to follow these instructions may result in serious injury to vehicle occupant(s).

NOTE:  Part Three may only be performed once the Glass Company repair procedures have been completed.

11. Remove the protective cover from the vehicle and clean off any dirt and debris.

12. Re-install all previously removed components by reversing steps 1-2.

13. After the windshield has been properly installed and the urethane has dried per the manufacturer’s instructions, carry out the Image Processing Module A (IPMA) Camera alignment using a scan tool.

 


CERTAIN 2022 MODEL YEAR BRONCO AND RANGER VEHICLES — WINDSHIELD ADHESION REPAIR

 

SERVICE PROCEDURE – GLASS COMPANY INSTRUCTIONS

BRONCO VEHICLES

NOTE:  These instructions are not intended to be followed from beginning to end. There are several locations where procedures must be completed by other groups before the procedure in these instructions can be resumed.

The instructions should be followed in this order.

1.  Body Shop Part One – Prepare vehicle for repairs – Separate attachment

2.  Glass Company Part One – Remove windshield – Steps 1-6 as required.

3.  Body Shop Part Two – Improve Flange adhesion – Separate attachment

4.  Glass Company Part Two – Install windshield – Steps 7-15

5.  Body Shop Part Three – Calibrate Image Processing Module A – Separate attachment

 

BODY SHOP PART ONE – SEPARATE ATTACHMENT

GLASS COMPANY – PART ONE

1.  Apply tape to the perimeter of the windshield to protect from paint damage. See Figure 1 as a locational reference.

NOTE: Tape off the roof panel near the centerline of the vehicle, where the roof extends forward. When using a fiber line to cut out the glass, the line will roll over the class A paint in the roof area, once tension is applied to it. If using a nylon style string, this will not damage the paint.

 

2. Remove the windshield using a fiber line cut out tool. See Figure 2.

 

3. Remove the tape from the A-pillar and roof edge.

4. Inspect the windshield for possible damage. Is there any damage to the windshield?

Yes – Replace the windshield. Proceed to Step 5.

No  – Re-install the original windshield. Proceed to Step 7 once Body Shop – Part Two has been completed.

NOTE: Damage to the alignment pins does not require windshield replacement.

5. Use glass cleaner to clean the surface of the new windshield to be installed.

6. Remove and transfer any necessary components onto the new windshield.

– Proceed to step 7 once Body Shop – Part Two has been completed.

 

BODY SHOP PART TWO – SEPARATE ATTACHMENT

GLASS COMPANY – PART TWO

NOTE:  Part Two may only be performed once the Body Shop repair procedures to the window flange have been completed.

7. Shave down the urethane on the original windshield until there is 1mm remaining. See Figure 3.

NOTICE: New or reused fixed glass must be installed within 2 hours of cutting the urethane adhesive. Exposed cut surfaces of urethane become oxidized and inactive beyond 2 hours, reducing the effectiveness of the repair bond.

 

Material (Steps 8-11): Sika® Aktivator PRO / Dow® BETAPRIME™ 5504G / Sika® Primer-207

8. Apply two coats of urethane body flange primer according to the manufacturer’s instructions to the entire windshield body flange at the urethane location.

– Allow dry time between each coat applied.

9. Apply two coats of window primer at any location where the paint layers have been damaged to provide environmental protection.

–  Allow dry time between each coat applied.

10. If the windshield is being replaced, apply window primer according to the manufacturer’s instructions to the new windshield.

–  Allow dry time per manufacturer’s instructions.

11. If the original windshield is being reused, apply window primer according to the manufacturer’s instructions to the fixed glass anywhere the urethane adhesive was completely removed.

– Allow dry time per manufacturer’s instructions.

12. Cut the urethane adhesive applicator tip to specification. See Figure 4.

Material: Sika® SikaTack® MACH 60 / Sika® SikaTack® MACH 30 / Dow® BETASEAL™ Express Material: Sika Tack ASAP Urethane Adhesive

 

13. Apply a urethane adhesive bead. See Figure 5.

1. Start and end at the original overlap points to prevent air and water leaks.

2. Apply a urethane adhesive bead 14 mm (0.551 in) high and 8 mm (0.314 in) wide on top of the original urethane adhesive bead location.

3. Make sure there are no gaps in the bead.

NOTICE: Make sure the urethane bead is uniform to prevent air and water leaks.

NOTE: The fixed glass must be installed within 10 minutes of applying the urethane adhesive.

NOTE: Use a power caulk gun that applies the urethane adhesive with less effort and a continuous bead.

 

14. Open the vehicle windows to prevent the air pressure of closing doors from compromising the urethane adhesive bond.

NOTICE: The door windows must be left open during the adhesive curing time.

15. Install the fixed glass to the vehicle.

1. Install the fixed glass, pressing firmly by hand to ensure a good bond.

2. Secure the fixed glass in the correct position with tape until the urethane adhesive has cured.

WARNING: Do not drive vehicle until the urethane adhesive seal has cured. Follow urethane adhesive manufacturer’s curing directions. Inadequate or incorrect curing of the urethane adhesive seal will adversely affect glass retention. Failure to follow these instructions may result in serious injury to vehicle occupant(s).

BODY SHOP PART THREE – SEPARATE ATTACHMENT

 


CERTAIN 2022 MODEL YEAR BRONCO AND RANGER VEHICLES — WINDSHIELD ADHESION REPAIR

SERVICE PROCEDURE – BODY SHOP INSTRUCTIONS

RANGER VEHICLES

NOTE:  These instructions are not intended to be followed from beginning to end. There are several locations where procedures must be completed by other groups before the procedure in these instructions can be resumed.

The instructions should be followed in this order.

1. Body Shop Part One – Prepare vehicle for repairs – Step 1

2. Glass Company Part One – Remove windshield – Separate attachment

3. Body Shop Part Two – Improve flange adhesion – Steps 2-9 as required.

4.  Glass Company Part Two – Install windshield – Separate attachment

5.  Body Shop Part Three – Calibrate Image Processing Module A – Steps 10-12

 

BODY SHOP PART ONE

1. Remove the cowl panel grille. Please follow Workshop Manual (WSM) procedures in Section 501-02.

 

GLASS COMPANY PART ONE – SEPARATE ATTACHMENT

BODY SHOP PART TWO

2. Cover/protect the body and interior of the vehicle with a one-time use, disposable drop plastic.

NOTE:  Ensure that the exposed headliner edge is fully covered.

3. Using a scraper, cut through the urethane bead vertically down to the painted surface to create a starting point.

– Once reaching the painted surface, pry one side of the bead up with the scraper.

– Using fingers, work to peel the urethane off the windshield body flange.

4. In areas where the urethane peeled up cleanly:

–  Use 400-600 grit sandpaper or a fine Scotch-Brite pad.

–  Manually scuff the clear coat lightly until it displays a white haze.

– Be sure to only abrade the flange.

–  See Figure 1.

 

5. In areas where the urethane did not peel up cleanly:

–  Use a Scotch-Brite 3M Roloc disk to remove all remaining urethane from the flange.

– Attempt to minimize abrasion to the painted surface.

– See Figure 2.

 

6. Clean off the entire windshield flange from all dirt and debris.

7. Using Isopropyl Alcohol and a lint-free cloth, clean off the flange surface. Allow one minute for the Isopropyl Alcohol to evaporate.

8. Apply tape to the edges of the windshield flange to protect the surface of the vehicle. See Figure 3.

 

9. Apply one coat of any Ford approved epoxy based repair primer to any spots where the roloc disk was used to grind off the urethane. See Figure 4.

– Allow time for the primer to dry per the manufacturer’s instructions.

 

GLASS COMPANY PART TWO – SEPARATE ATTACHMENT

BODY SHOP PART THREE

NOTICE: The door windows must be left open during the adhesive curing time.

WARNING: Do not drive vehicle until the urethane adhesive seal has cured. Follow urethane adhesive manufacturer’s curing directions. Inadequate or incorrect curing of the urethane adhesive seal will adversely affect glass retention. Failure to follow these instructions may result in serious injury to vehicle occupant(s).

NOTE:  Part Three may only be performed once the Glass Company repair procedures have been      completed.

10. Remove the protective cover from the vehicle and clean off any dirt and debris.

11. Re-install all previously removed components by reversing step 1.

12. After the windshield has been properly installed and the urethane has dried per the manufacturer’s instructions, carry out the Image Processing Module A (IPMA) Camera alignment using a scan tool.

 


CERTAIN 2022 MODEL YEAR BRONCO AND RANGER VEHICLES — WINDSHIELD ADHESION REPAIR

SERVICE PROCEDURE – GLASS COMPANY INSTRUCTIONS

RANGER VEHICLES

NOTE:  These instructions are not intended to be followed from beginning to end. There are several locations where procedures must be completed by other groups before the procedure in these instructions can be resumed.

The instructions should be followed in this order.

1. Body Shop Part One – Prepare vehicle for repairs – Separate attachment

2. Glass Company Part One – Remove windshield – Steps 1-6 as required.

3. Body Shop Part Two – Improve Flange adhesion – Separate attachment

4. Glass Company Part Two – Install windshield – Steps 7-15

5. Body Shop Part Three – Calibrate Image Processing Module A – Separate attachment

 

BODY SHOP PART ONE – SEPARATE ATTACHMENT

GLASS COMPANY – PART ONE

1. Apply tape to the perimeter of the windshield to protect from paint damage. Multiple layers of tape may be required. See Figure 1 as a locational reference.

2. Remove the windshield using the cold knife method to cut the urethane from the outside of the vehicle provided the blade can reach the bead.

NOTE:  It is suggested to use multiple blade lengths. See Figure 2.

 

3. Remove the tape from the A-pillar and roof edge.

4. Inspect the windshield for possible damage. Is there any damage to the windshield?

Yes – Replace the windshield. Proceed to Step 5.

No  – Re-install the original windshield. Proceed to Step 7 once Body Shop – Part Two has been completed.

NOTE: Damage to the alignment pins does not require windshield replacement.

5. Use glass cleaner to clean the surface of the new windshield to be installed.

6. Remove and transfer any necessary components onto the new windshield.

– Proceed to step 7 once Body Shop – Part Two has been completed.

 

BODY SHOP PART TWO – SEPARATE ATTACHMENT

GLASS COMPANY – PART TWO

NOTE:  Part Two may only be performed once the Body Shop repair procedures to the window flange have been completed.

7. Shave down the urethane on the original windshield until there is 1mm remaining. See Figure 3.

NOTICE: New or reused fixed glass must be installed within 2 hours of cutting the urethane adhesive. Exposed cut surfaces of urethane become oxidized and inactive beyond 2 hours, reducing the effectiveness of the repair bond.

 

Material (Steps 8-11): Sika® Aktivator PRO / Dow® BETAPRIME™ 5504G / Sika® Primer-207

8. Apply two coats of urethane body flange primer according to the manufacturer’s instructions to the entire windshield body flange at the urethane location.

– Allow dry time between each coat applied.

9. Apply two coats of window primer at any location where the paint layers have been damaged to provide environmental protection.

–  Allow dry time between each coat applied.

10. If the windshield is being replaced, apply window primer according to the manufacturer’s instructions to the new windshield.

–  Allow dry time per manufacturer’s instructions.

11. If the original windshield is being reused, apply window primer according to the manufacturer’s instructions to the fixed glass anywhere the urethane adhesive was completely removed.

– Allow dry time per manufacturer’s instructions.

12. Cut the urethane adhesive applicator tip to specification. See Figure 4.

Material: Sika® SikaTack® MACH 60 / Sika® SikaTack® MACH 30 / Dow® BETASEAL™ Express Material: Sika Tack ASAP Urethane Adhesive

13. Apply a urethane adhesive bead. See Figure 5.

1. Start and end at the original overlap points to prevent air and water leaks.

2. Apply a urethane adhesive bead 14 mm (0.551 in) high and 8 mm (0.314 in) wide on top of the original urethane adhesive bead location.

3. Make sure there are no gaps in the bead.

NOTICE: Make sure the urethane bead is uniform to prevent air and water leaks.

NOTE: The fixed glass must be installed within 10 minutes of applying the urethane adhesive.

NOTE: Use a power caulk gun that applies the urethane adhesive with less effort and a continuous bead.

 

14. Open the vehicle windows to prevent the air pressure of closing doors from compromising the urethane adhesive bond.

NOTICE: The door windows must be left open during the adhesive curing time.

15. Install the fixed glass to the vehicle.

1. Install the fixed glass, pressing firmly by hand to ensure a good bond.

2. Secure the fixed glass in the correct position with tape until the urethane adhesive has cured.

WARNING: Do not drive vehicle until the urethane adhesive seal has cured. Follow urethane adhesive manufacturer’s curing directions. Inadequate or incorrect curing of the urethane adhesive seal will adversely affect glass retention. Failure to follow these instructions may result in serious injury to vehicle occupant(s).

BODY SHOP PART THREE – SEPARATE ATTACHMENT

 


22C12 – CERTAIN 2022 FORD BRONCO AND RANGER VEHICLES – INADEQUATE WINDSHIELD ADHESION

Chronology of Defect / Noncompliance Determination 

 

Provide the chronology of events leading up to the defect decision or test data for the noncompliance decision.

 

April 2022- On April 07, 2022, an issue was introduced to Ford’s Critical Concern Review Group (CCRG) to review windshield installation control plan data from the Michigan Assembly Plant (MAP). On the previous day, a reported urethane concern from a customer’s Bronco was reviewed.  In expanding the search, data indicated that eight of 65 units did not meet Ford’s internal adhesion control plan requirements.  These eight units had build dates from January 15 to January 25, 2022.

 

From April 07 to April 13, 2022, additional Bronco windshield cutout tests were conducted and 16 additional units that did not meet Ford’s enhanced internal threshold adhesion were identified.  These units were built between January 15 to March 30, 2022.  Ford further identified that the Ranger windshield installation process is similar to Bronco. Subsequent windshield cutout tests conducted on Ranger units found three units out of 14 that did not meet Ford’s internal windshield adhesion threshold. These three units were built between January 10 to March 29, 2022.

 

At the direction of the CCRG, Ford Engineering and MAP initiated an investigation on April 21, 2022,  into potential contributors to reduced windshield adhesion and variables affecting bonding results, including ambient temperature and humidity, oven settings and variation, presence of contaminants (e.g. silicone and fluorine), phthalate levels, clearcoat thickness and others.  While some evidence was found that could relate to each variable, no conclusions were reached.

 

May 2022- From May 06, 2022 to June 02, 2022, an expanded review of MAP control plan data and additional cutout data for vehicles at MAP identified bonding performance that did not meet Ford’s internal requirements on vehicles produced during the build date ranges identified above. The level of windshield adhesion performance observed from the panel testing and vehicle glass cut-outs called into question whether the affected units would meet the 50% adhesion requirements of FMVSS 212. The cause for this issue remains unknown at this time.

 

Ford is not aware of any accidents or injuries pertaining to this issue.

 

On June 17, 2022, Ford’s Field Review Committee reviewed the concern, and approved a field action for a potential noncompliance in the listed population.

 

###

June 24, 2022

 


2 Affected Products

Vehicles

MAKE MODEL YEAR
FORD BRONCO 2022
FORD RANGER 2022

 


4 Associated Documents

Miscellaneous Document – Chronology of Defect

RMISC-22V451-9214.pdf 70.693KB

RMISC-22V451-9214

 


Noncompliance Notice 573 Report

RCLRPT-22V451-6423.PDF 215.38KB

RCLRPT-22V451-6423

 


Recall Acknowledgement

RCAK-22V451-1967.pdf 645.124KB

RCAK-22V451-1967

 


Manufacturer Notices(to Dealers,etc) – Dealer Bulletin re NEW VEHICLE DEMONSTRATION / DELIVERY HOLD – Compliance Recall 22C12 Certain 2022 Model Year Bronco and Ranger Vehicles Windshield Adhesion Repair

RCMN-22V451-4233.pdf 4560.447KB

RCMN-22V451-4233

 


Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=22V451&docType=RCL

 


 

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