S
TECHNICAL SERVICE BULLETIN 24-2080
Soft Top Roof - Headliner Detaching From Soft Top Material 19 March
This bulletin supersedes 23-2024. Reason for update: add rivets to the parts list
Model:
Ford
2021-2023 Bronco
Issue: Some 2021-2023 Bronco vehicles equipped with a factory soft top roof may exhibit a headliner that is
detaching from the soft top material. This may be due to the factory installation process. To correct this condition,
follow the Service Procedure to reattach the headliner or replace the soft top roof material.
Action: Follow the Service Procedure to correct the condition on vehicles that meet all of the following criteria:
* 2021-2023 Bronco
+ Equipped with a factory soft top roof
+ Headliner detaching from the soft top material
Parts
Service Part Claim Package Order Description
Number Quantity Quantity escriptio!
164-R9343 As Needed As Needed 1 Rotunda part
Obtain Locally As Needed As Needed Gorilla® Heavy Duty Spray
Adhesive
Obtain Locally As Needed As Needed Lint-Free Towel |
Obtain Locally As Needed As Needed Powder-Free Disposable Gloves |
Parts - Parts To Inspect And Replace Only If Necessary
Service Part Number | Claim Quantity Package Order Quantity | Number in Package
M2DZ-7852700-BD | If Needed (1 possible) | If Needed (1 Possible) Soft Top Material
W790580-S900 If Needed (25 Possible)| IfNeeded(7 Possible) | = ==4 ~~ [Rivet
Claim Quantity refers to the total number of individual pieces required to repair the vehicle.
Package Order Quantity refers to the amount of the service part number package(s) required to repair the vehicle.
Number In Package refers to the number of individual pieces included in a service part number package.
As Needed indicates the amount of the part may vary and/or is not a whole number. Parts can be billed out as non-
whole numbers, including less than 1.
If Needed indicates the part is not mandatory.
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

ge Operation a
2021-2023 Bronco: Reattach Or Replace The Soft Top Roof Material Following The MT242080 | Actual
Service Procedure (Do Not Use With Any Other Labor Operations) Time

Repair/Claim Coding
Causal Part: 7852700
Condition Code:
Service Procedure
1. The soft top material has 2 separate sections of headliners, refer to Figure 1 for locations. Are either of the 2
headliners completely detached from the soft top material and/or damaged, such as stretched, cut and/or warped?
(Figures 1-3)
(1). Yes - replace the soft top material. Refer to WSM, Section 501-18A. Repair is complete.
(2). No - proceed to Step 2.
Figure 1 - View from underside of the soft top assembly. Both headliner locations shown.
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Figure 2 - Example of an undamaged, partially detached headliner that can be repaired

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Figure 3 - Example of an undamaged, partially detached headliner that can be repaired
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2. Has an attempt already been made to reattach either headliner using glue, tape, or any kind of adhesive?
(1). Yes - replace the soft top material. Refer to WSM, Section 501-18A. Repair is complete.
(2). No - proceed to Step 3.

3. With help from an assistant, remove the soft top assembly from the vehicle and place it on a large clean tarp or
blanket on the ground. Refer to WSM, Section 501-18A > Removal and Installation > Soft Top Assembly.

4. With help from a 2nd person, turn the soft top assembly upside down keeping the soft top assembly on the clean
tarp or blanket. Carefully open the soft top assembly so that it is in the fully open position and be sure it remains
upside down. (Figure 4)

Figure 4

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5. Use a damp, clean, lint-free cloth to wipe down the entire inside fabric of the soft top material and headliners. If
needed, a vacuum can be used to assist with cleaning.
6. Reattach the applicable headliner(s) to the soft top material using the Gorilla® Heavy Duty Spray Adhesive.
(1). Perform this step on all sections of the headliner(s) that have become partially detached.
(2). Prepare the soft top material and headliner(s) for reattachment with the spray adhesive by taping off the
surrounding areas with painter’s tape. Use paper and/or cardboard to add further protection. Only the inner
section of the headliner (that has detached) and the mating surface of the headliner (soft top material) are
sprayed with the adhesive. Make sure that adhesive overspray does not occur to the surrounding areas or
components, or soft top material replacement may be required. (Figure 5)
Figure 5 - Showing a properly covered area ready for spray adhesive

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(3). Follow the directions on the can to apply the Gorilla® Heavy Duty Spray Adhesive to the inside portions of the
headliner(s) and the portions of the soft top material that it will adhere to. Wear powder-free disposable gloves
during this process.
(4). Once the spray adhesive is applied to the mating surfaces, work quickly to lay the headliner(s) back into place
on the soft top material, starting in the middle working outwards. Use your hands to apply outward pressure on the
headliner to remove bubbles and/or creases and to be sure the headliner is in the correct/original location,
(5). Remove all protective material (tape/paper/cardboard). Proceed to Step 7.

7. Install 3M™ Film Tape 9343 over the cross-car headliner seams.
(1). Tape all 3 cross-car headliner seams regardless of if they were becoming partially detached or not. Refer to
Figure 6 for cross-car headliner seam locations.

Figure 6 - Showing all 3 headliner seams that must be taped

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(2). Place a 50 Ib. (22.6 kg) sandbag (or similar item) on each the side of the frame to weigh down the raised
hinged sections of the frame. This flattens the soft top assembly for easier application. If needed, place a clean
cloth underneath the sandbags to prevent the soft top assembly from getting dirty. Refer to Figure 7.
Figure 7 - Sandbag shown on top of frame hinge location. Left side shown, right side similar.
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(3). Install the 1 in. (25 mm) wide film tape with half of its width on the headliner and half on the soft top material to
create a permanent bond between the two surfaces. To aid in installation, create a guide for the film tape by
placing pieces of painter’s tape exactly 0.5 in. (13 mm) from the headliner edge, approximately every 6 in. (150
mm) apart, across the entire length of the seam. Refer to Figure 8.
Figure 8

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(4). Wear powder-free disposable gloves while handling the film tape. Oil from hands can reduce the tape’s
adhesion if contact occurs.
(5). Cut one continuous section of film tape to a total length of at least 100 in. (2540 mm).
(6). Set the center point of the cut section of film tape on the middle of the soft top assembly. This leaves extra
tape on each end of the soft top assembly. Beginning on one side, approximately 12 in. (30 cm) away from one
edge of the seam, peel the tape backing in small increments as needed (do not remove the entire length of the
tape backing all at once) and lightly install the tape following the 0.5 in. (13 mm) tape guidelines. Be sure that half
of the tape width is on the headliner and the other half on the soft top material, creating a straight/uniform line,
refer to Figures 9-10. Do not stretch the tape at any point before or during the application. Film tape is extremely
pliable which allows it to have excellent adhesion to the fabric. If it is installed while being stretched, it retracts
over time which causes it to lose adhesion, refer to Figure 10.
Figure 9 - Showing proper tape Installation following the taped guidelines.

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Figure 10 - Showing proper tape installation. Do not stretch tape and only remove backing as needed.

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(7). When the section of film tape reaches the end of the headliner seam, continue to tape in a straight line all the
way to the edge of the soft top seam. Allow the tape to stay loose during application. Cut the end of the film tape
so that it ends just before the soft top material edge but do not tape past the edge, which runs perpendicular to
the tape routing. Be sure that 100% of the film tape is secured and flat to the surface. Do not leave any sections of
tape loose/unattached, as this causes tape to peel over time. Perform this step on the opposite edge of the
section of film tape, then proceed to the next step. (Figure 11)

Figure 11 - Showing proper tape installation on the edge of the soft top material.

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(8). Inspect the installed film tape for straightness, proper 50/50 adhesion to the headliner and soft top roof
material across the entire length of the headliner, film tape peeling (occurs when tape is stretched during
installation), and both vertical edges to ensure proper adhesion with no lift of the tape present. If any of these
problems exist, perform Step 7 again with a fresh section of film tape.
(9). While wearing powder-free gloves, use hands to apply pressure across the entire length of the section of film
tape.
(10). Protect the entire length of the soft top frame bow covers with painter's tape, then use a rubber 1.5 in. J-
roller to fully press the film tape into the soft top material.
(11). Perform Steps 7(3) - 7(10) on the remaining 2 headliner seams.

Figure 12 - Showing a complete installation of film tape along all three cross-car headliner seams
(12). Reinspect all 3 installed sections of film tape. Inspect for tape straightness, proper 50/50 adhesion to the
headliner and soft top roof material across the entire length of the headliner, film tape peeling (occurs when tape
is stretched during installation), and both vertical edges to ensure proper adhesion with no lift of the tape present.
If any of these problems exist, repeat Step 7 on any failed sections using a fresh piece of tape.

8. Use a damp, clean, lint-free cloth to wipe down the entire inside section of the soft top material and headliners.

9. With help from an assistant, carefully place the soft top assembly in the fully closed position. Refer to WSM,

Section 501-18A > Removal and Installation > Soft Top Assembly.
10. With help from an assistant, install the soft top assembly back onto the vehicle. Refer to WSM, Section 501-18A >
Removal and Installation > Soft Top Assembly.

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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