NHTSA ID Number: 10203652
Manufacturer Communication Number: TSB 21-2403
TSB/Document Date: 2021-12-01
Summary
Some 2021 Bronco vehicles may experience a water leak that originates from the left and/or right A-pillars and/or the windshield header. This may be due to excessive gaps in the body seams from the factory. To correct the condition, follow the Service Procedure to reseal the affected body gaps and replace the front header seal.
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TECHNICAL SERVICE BULLETIN
Water Leak From A-Pillars And/Or Windshield
Header
21-2403
15 November 2021
Model:
Ford
2021 Bronco
Issue: Some 2021 Bronco vehicles may experience a water leak that originates from the left and/or right A-Pillars
and/or the windshield header. This may be due to excessive gaps in the body seams from the factory. To correct the
condition, follow the Service Procedure to reseal the affected body gaps and replace the front header seal.
Action: Follow the Service Procedure steps to correct the condition if the vehicle meets all of the following criteria:
• 2021 Bronco
• Water leak originating from one of the following:
- Left A-pillar
- Right A-pillar
- Windshield header
Parts
Service Part Number Quantity
M2DZ-7803110-B
1
Description
Header Seal
Obtain Locally
As Needed 3M™ Strip-Calk
Obtain Locally
As Needed Alcohol Wipes
Quantity refers to the amount of the service part number required to repair the vehicle.
As Needed indicates the amount of the part may vary and/or is not a whole number. Parts can be billed out as nonwhole numbers, including less than 1.
Warranty Status: Eligible under provisions of New Vehicle Limited Warranty (NVLW)/Service Part Warranty
(SPW)/Special Service Part (SSP)/Extended Service Plan (ESP) coverage. Limits/policies/prior approvals are not
altered by a TSB. NVLW/SPW/SSP/ESP coverage limits are determined by the identified causal part and verified
using the OASIS part coverage tool.
Labor Times
Operation
Time
No.
Description
2021 Bronco: Replace The Header Seal Following The Service Procedure (Do Not Use With
Any Labor Operations Outside Of This Article)
212403A
2.7
Hrs.
Additional Time To Remove And Install The Roof Rack If Equipped (Can Be Claimed With
Operation A)
212403B
0.3
Hrs.
Additional Time To Service Carpet For Dampness And/Or Odor (Can Be Claimed With
Operation A)
MT212403 Actual
Time
Repair/Claim Coding
Causal Part:
7803110
Condition Code: 01
Service Procedure
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1. Remove both windshield trim covers by pressing the button on the rear of the cover and rotating it forward. If a
roof rack is installed on the vehicle, it will need to be removed using the assistance of a second person. Refer to
the vehicle’s Digital Owner’s Manual for removal instructions. (Figure 1)
Figure 1
2. Remove/retract the front roof sections.
(1). Vehicles equipped with a hard top roof, remove only the front 2 sections covering the driver and passenger
seats. Refer to the Digital Owner’s Manual, Removable Vehicle Components > Removable Hard Top > Removing
and Installing the Hard Top.
(2). Vehicles equipped with a soft top roof, place it in the partially open position. Refer to the Digital Owner’s
Manual, Removable Vehicle Components > Removable Soft Top > Opening and Closing the Soft Top.
3. Remove the windshield header trim panel. Refer to Workshop Manual (WSM), Section 501-05, Interior Trim and
Ornamentation > Removal and Installation > Windshield Header Trim Panel.
4. Remove the header seal.
(1). Remove the 5 center bolts and nuts securing the header seal to the body. (Figure 2)
Figure 2
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(2). Remove the 4 bolts (2 on each side) securing the header seal to the body. (Figure 3)
Figure 3
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(3). Remove the 2 pushpin fasteners (1 on each end). (Figure 4)
Figure 4
(4). Remove the header seal from the vehicle.
5. Clean the header seal mating surface on the body by removing all residual sealer left over from the old header
seal. Use a plastic scraper and isopropyl alcohol wipes to clean the surface without harming the painted surface. If
any painted surfaces are scratched during the cleaning process, touch up these areas with paint (covering any
exposed metal) prior to proceeding.
6. Follow the instructions on the container to apply 3M™ Strip-Calk to the exposed body seams starting at the roof
rack trim cover area and ending at the corner seal where the body seam ends. Do not leave a gap between the
edge of the caulk and the corner seal. (Figures 5-8)
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Figure 5
Figure 6
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Figure 7
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Figure 8
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7. Peel the plastic backing from the new header seal to expose the bottom sticky surface applied by the
manufacturer.
8. Carefully install the header seal on the vehicle ensuring all attachment holes line up to the vehicle attachment
points.
9. Install all header seal attachments.
(1). Tighten the 5 center bolts and nuts securing the header seal to the body to 9 Nm (80 lb-in). (Figure 2)
(2). Tighten the 4 bolts (2 on each side) securing the header seal to the body to 3 Nm (26 lb-in). (Figure 3)
(3). Install the 2 pushpin fasteners, 1 located at each end. (Figure 4)
10. Inspect the header seal to body surface by lightly pulling up on the edges of header seal. If any gaps are found in
the sealing surface, fill the gaps using 3M™ Strip-Calk.
NOTE: The header seal must be completely sealed to the body. Any gaps between the header seal and body
may result in further water leaks.
11. Install the windshield header trim panel. Refer to WSM, Section 501-05, Interior Trim and Ornamentation >
Removal and Installation > Windshield Header Trim Panel.
12. Pull/remove the cord that runs along the inside of the header seal groove.
13. Install both windshield trim covers. If a roof rack was installed on the vehicle, it will need to be reinstalled with the
assistance of a second person. Refer to the vehicle’s Digital Owner’s Manual for installation instructions. (Figure 1)
14. Return the roof to a fully closed position. Refer to Step 2 for roof operating instructions.
15. If equipped, inspect the carpet for dampness and/or odor and service as necessary.
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© 2021 Ford Motor Company
All rights reserved.
NOTE: The information in Technical Service Bulletins is intended for use by trained, professional technicians with the knowledge, tools, and
equipment to do the job properly and safely. It informs these technicians of conditions that may occur on some vehicles, or provides information
that could assist in proper vehicle service. The procedures should not be performed by "do-it-yourselfers". Do not assume that a condition
described affects your car or truck. Contact a Ford or Lincoln dealership to determine whether the Bulletin applies to your vehicle. Warranty Policy
and Extended Service Plan documentation determine Warranty and/or Extended Service Plan coverage unless stated otherwise in the TSB article.
The information in this Technical Service Bulletin (TSB) was current at the time of printing. Ford Motor Company reserves the right to supersede
this information with updates. The most recent information is available through Ford Motor Company's on-line technical resources.
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TSB/Document ID: TSB 21-2403
Replacement Service Bulletin Number:
MFR Communication Date: 2021-11-16
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: STRUCTURE:BODY:ROOF AND PILLARS
MFR Component System:
MFR Component Subsystem:
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