Ford designed the 2022 Bronco Raptor to be big. Too big, it turned out, for the assembly line.
The ultra-rugged version of the off-road SUV, set to go on sale this summer, has 14 inches of suspension travel in the rear, the same as the 37-inch wheel package on the F-150 Raptor but significantly more than the base Bronco, which it shares a home with at Ford’s Michigan Assembly Plant outside Detroit.
That meant the vehicle would get stuck during the build process, according to Derek Bier, vehicle engineering manager for Ford Performance.