Ok, i know that there are as many posts about this as the rear window not working and such but the reason i am posting is because i don't just have the usual cracks at the end of the raingutters. on the drivers side, there is an actual bend in the metal going from the end of the raingutter diagonally down towards the front of the vehicle that is about 4" long. the bend hasnt always been there and it couldnt have been from anything hitting it so i am quite baffled. i am just curious as to how i should go about fixing it. i will attach a picture soon so that it will be easier to understand it. any ideas or suggestions for fixing this are very welcome.



1985 Blue and White Bronco XLT, 351HO 4bbl, C6, NP208 ,9" 3.55 limited slip, Warn Premium Hubs, Quad Front Shocks, Dual Flowmaster 50's, BFG 32x11.5 ATko's

 

The original TSB on that was from around '86 and Ford never changed the design. The repair kit isn't available any more, but there wasn't much to it. Here's the text of that TSB:
---------------------------------------------------------------------
Article No.
96-20-11
SHEET METAL-ROOF CRACKS-REPAIR PROCEDURE
LIGHT TRUCK: 1980-96 BRONCO

This TSB is being republished in its entirety to include Bronco through the current model year of 1996.
ISSUE: Cracks may appear on the roof panel or on the corner panel sheet metal near the end of the drip rail at the B-pillar.
ACTION: Repair roof sheet metal cracks by using the Roof Repair Kit (F5TZ-9850223-A). Refer to Instruction Sheet #6661, included in the kit, for service details.
NOTE: BE SURE TO REPAIR BOTH SIDES AT THE SAME TIME. IF ONLY ONE SIDE IS CRACKED, ALSO REPAIR THE SIDE THAT IS NOT CRACKED.
The Roof Repair Kit (F5TZ-9850223-A) contains the following:
One (1) Reinforcement -Body Side RH
One (1) Reinforcement -Body Side LH
One (1) Reinforcement -Roof Inner Panel RH
One (1) Reinforcement -Roof Inner Panel LH
Two (2) Plates -Roof Side Rail Enforcement
One (1) Epoxy -2 Part
Fourteen (14) Rivets
One (1) Instruction Sheet (I.S. #6661)
PART NUMBER
F5TZ-9850223-A
PART NAME
Roof Repair Kit
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 95-14-9
WARRANTY STATUS: Eligible Under the Provisions of Bumper-to-Bumper Warranty Coverage for 1992-96 Vehicles; Basic Coverage for All Others
OPERATION
962011A
DESCRIPTION
Repair Roof Cracks (Includes Installation of New Headliner if Necessary)
TIME
3.5 Hrs.
DEALER CODING
BASIC PART NO. 7050202
CONDITION CODE 01
OASIS CODES: 106000, 110000
--------------------------------------------------------------------
You can't buy it, but this is the most recent price I could find for the kit: $152.73

 

Re: the kit -

I had my local dealer look for one just for grins - his computer said there was one a a dealership in Pennsylvania, but when we called it wasn't there $162.13 for the kit.

I wonder what it would require to either get somebody to make them on the aftermarket, or if anyone has one, get the dimensions and instructions so we could make our own?

I'm keeping my eyes open - maybe I'll get lucky....

msautry

 

Heck, I'd be happy to see that IS 6661!

 

hey, I have similar cracks on my 89 bronco on the ends of the rain gutters would the same kit work on the 89 bronco?

 

I have those cracks as well. In fact, water gets down into the side compartment and from there leaks to the carpet. I need to fix it someday. I will probably just sand all the rust off and do a little bondo work.

Brian

 

Bondo is the best stuff ever for small repairs definatly do it. I did it to my rear wheel wells up here in the north east their salts best freind and they were gone so this past summer I got a bunch of bondo and fixed it up. I haven't done it to the gutters yet though

 

I emailed ford about this kit I will let you guys know there reply.

 

Ford called me back today and gave me two numbers to try. www.obsolete.com 1800-933-6731 and www.greensalescompany.com 1-800-543-4959. Greensales needs a part number to do a search and they did not have this kit(7050202) on the web search, but if you call I think they have other places to look. Obsolete web site is under construction and I did not call the number. Ford told me these two places deal with diccontiued and hard to find parts. I hope this helps someone

 

A note on the bondo - don't waste your time! I have a 90 Bronco XLT with the same problem - cracks on both sides at the rain gutters, and have tried to fix one side with bondo. There is just too much flex in the roof at this point, so the bondo will crack & drop out within days of fixing. You might try a flexible body filler or something of the like, or get the cracks welded for a proper fix.

Pooks

90 Bronco XLT 5.8L (Casper)

 

Bondo sucks. If you use it to fix rust, the rust always comes back worse from under the bondo after a couple of years, unless you are VERY thorough about removing ALL the rust. Even then, you should put some sheet metal or something under the cut out area, and just put a thin layer of bondo over, or else the bondo will eventually cave in. If you put bondo anywhere that flexes, it will crack. Do the repair right by replacing the damaged metal part with another metal part. I would only use bondo on a beater if I wanted to quickly fix a hole that was leaking or something, and I would be prepared to do it every other year or so.

 

Silicone. Just clear RTV........

 

I definitely will put slicone on the inside where it leaks, but it will still pool there. Anyone ever use JB Weld for body work? I've used it on a gas tank on a motorcycle and it worked great.

Brian
88 351 EFI

 

Ok Guys,

I just bought the F5TZ-9850223-A Repair kit for my Bronco! it wasn't cheap - $165.

Guess what? The dealer has 1 more kit! :-X12

Atchinson Ford Sales Inc
9800 Belleville Rd
Belleville, MI 48111
(734)697-9161

I spoke with Carl, and he is more than happy to help ya out.. I gave him a heads up that I am sure that the Repair kit would probably be sold by the end of the week...

 

I don't think I want to spend $165 for those little cracks. But let us know how it turns out when you fix yours.

Brian