Extremely weak cabin roof

[jorosz0309]

I deal with a similar condition in my career.

This sounds like “oil-canning”.

Oil-canning typically occurs (in my business) with cold rolled steel in areas where both ends of the panel are “pinned” and cannot allow for thermal expansion and contraction of the steel. If the heat of the dryers and the drastic temperature change is causing the oil canning then the subsequent temperature change leaving the car wash lets the panel “pop” back into place. To relieve this, steel will often be formed with a slight bend, ridges, or perforations in the panel to allow the panel to flex during temperature changes.

Fortunately, oil canning does NOT affect the structural integrity of the steel. It’s just “physics”.

I will concede that Ford should’ve taken more preventative measures to reduce the oil-canning, but the fact that it’s popping back into place likely mitigated the need for a change. I could be wrong but my understanding with the Colorado/Canyon service bulletin was that it wasn’t going back to its original shape after leaving the car wash.

Regarding structural integrity of the roof. Everything that keeps the roof from collapsing during a roll is hidden under the steel. I wouldn’t concern myself with the oil-canning unless it damages the roof or paint in some fashion.

I'm guessing you are right. I have a large steel basin sink at home and if I have the stopper in the drain and pour boiling hot water in it to strain noodles, I get the same flex / pop and often the drain plug will pop out if it's in. Follow that by running some cold water and you get another flex as it contracts. I've only used touchless car washes with my truck and here in Minnesota that sometimes means very drastic temperature changes. So I've heard the flex sound myself, though I've never had my Aux controls pop out. Like you, I'd venture a guess that it's temperature related (cold water, warm blowers?), and not due to the power of the blowers. I got my truck pretty early (March '24) and it's seen weekly touchless washes since then, much of that in Minnesota winter, without issue. The OP may want to take their dealer contact on a drive through the car wash.

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[AlpineBike]

I deal with a similar condition in my career.

This sounds like “oil-canning”.

Oil-canning typically occurs (in my business) with cold rolled steel in areas where both ends of the panel are “pinned” and cannot allow for thermal expansion and contraction of the steel. If the heat of the dryers and the drastic temperature change is causing the oil canning then the subsequent temperature change leaving the car wash lets the panel “pop” back into place. To relieve this, steel will often be formed with a slight bend, ridges, or perforations in the panel to allow the panel to flex during temperature changes.

Fortunately, oil canning does NOT affect the structural integrity of the steel. It’s just “physics”.

I will concede that Ford should’ve taken more preventative measures to reduce the oil-canning, but the fact that it’s popping back into place likely mitigated the need for a change. I could be wrong but my understanding with the Colorado/Canyon service bulletin was that it wasn’t going back to its original shape after leaving the car wash.

Regarding structural integrity of the roof. Everything that keeps the roof from collapsing during a roll is hidden under the steel. I wouldn’t concern myself with the oil-canning unless it damages the roof or paint in some fashion.

This is not what’s going on. The panel is only spot welded into place.
It’s like 24ga. metal. The air dryers are just deforming it.