Stress Cracks

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Feb 21, 2005 | 09:56 AM

JRB327

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Stress Cracks

I have a 92 Bronco XLT, believe it or not it just developed two stress cracks on each side of the rain gutters on the roof. A friend of mine told me that this was covered by Ford but not made available to the public. Any way to find out if they will still make the repairs??

92 302 Full size, K&N INtake-31" Tires, Rancho Shocks and only 172K ???

Feb 21, 2005 | 10:12 AM

94 XLT White/ Silver 302

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From: VB. Virginia

Let me be the first to wellcome you to FTE. If you do a search on stress cracks you will find a lot of info. I have stress cracks also. From what I understand Ford will not repair the cracks any longer. Ford made a repair kit but it is no longer available. All Bronco's from 80-95 have this problem. I believe the problem was fixed on the 96's

Feb 21, 2005 | 10:25 AM

kameronth

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From: North Dakota

I fixed mine with a clear tube of silicone!

Feb 21, 2005 | 05:51 PM

JRB327

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I guess its a good thing silicon comes in black

thanks for the reply

Feb 22, 2005 | 06:12 AM

LilDuke

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From: Danville, Pa

I have the same problem on my 87. To compound it, Preveiously removed grab bar(poorly patched) cracked at same spot. This spring when it warms up I am going to grind that entire area strait down to metal and cut out crack. Then I will peer inside to devise a way to create a little beefier pillar( corrigated cardboard style) Then weld the heck out of it. Then finnish it off with a high quality (rustoleium

) paint job. Good luck, Dave

Feb 26, 2005 | 11:28 AM

spaceganja

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From: near detroit Michigan

the stress crack developes because these Bronco's use the same frame as the 4wd pickup...which flexes the bed, and cab apart from eachother. I've put a lot of thought into fixing my stress cracks in my 84, but I can't think of a way that will fix that and not just move the stress point to a different location. Maybe seperating the cab from the bed, but in a Bronco...that would be a mess!

Feb 26, 2005 | 03:25 PM

justshootme84

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From: SE Texas

IF you do a search, there was a thread or two way back about the Ford repair kit. I think the consensus was that it wan't too good, expensive ($120), and hard to find even then. Maybe can find one on ebay. The silicone works fine for sealing the cracks so water doesn't get inside, but welding them is the best way to go. I had mine done when doing the body work for the paint job.