Ford Broncos by the Thousands SUVs parked, awaiting quality checks



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Mike Webb of the Bronco6G Forum filmed thousands of Ford Broncos parked near the Michigan assembly plant. Motor1.com contacted the automaker to find out what was going on. A spokesperson told us that these SUVs await quality checks before shipping them to showrooms.

If this explanation is correct, it looks like Ford needs to beef up its QA team because the Bronco is in high demand. The dealers would love to have these SUVs for sale. Also, leaving vehicles outside at least leaves the possibility of them being damaged in some way.

Gallery: 2021 Ford Bronco production

There were quality control issues with the first copies of the Bronco. One issue was with the hardtop which included a honeycomb or snakeskin pattern appearing on the outside of the panels. Inside, the headliner separated from the roof.

The photos also showed that the side play of the convertible top mechanism could strike the roll bar when raising or lowering the roof. This caused pieces of paint to peel off the roll bar.

Another problem with the roof was excessive wear on the fabric soft top. The problem would be related to the material rubbing against a piece of plastic when it is folded back.

There were also reports of a hissing sound from the mirrors and grille when the SUV was traveling over 30 miles per hour. Ford issued a technical service bulletin saying the noise was coming from airflow through a gap between the grille and the hood, and the company said it was working on an improved gasket.

Ford must resolve these issues because the Bronco is an early success and even wins customers from other brands. The Blue Oval indicates that 70 percent of SUV customers do not already own a Ford vehicle.

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