While driving on hwy (4 lanes each side) no cars on either side, no overpass or anything around to have caused any debris or flying objects, the sunroof spontaneously exploded and rained down glass on my daughter and myself. There was no noise of any object hitting the sunroof, you could tell it exploded on its own.

We were approx. 90 miles from home. We tried to clean up as much glass as possible but it was impossible and we continued to get cut from the glass. We had to drive home as the glass continued to rain down and also fly off the car causing possible harm to others. I filed a claim with State farm that day and was provided a list of places we had to use for service. I selected the location closest to my home and contacted them to arrange drop off, they were booked out 1 month before they could inspect the car.

I then selected an alternate location which was hard enough to get it switched with State Farm. Upon trying to change repair shops I discovered that State Farm sent it to a second party insurance company that had to approve as well. It took several days to get it approved then was informed there was a third insurance company that needed to approve. This caused additional time delay because no one would work with each other and I had to coordinate. State Farm would not allow the car rental until the repair shop had an available appt. This entire 2 weeks my daughter went without a car. State Farm only allows $500 towards a car rental which is approx. 2 weeks.

Once the car was dropped off and we had taken possession of the rental car I had to continue to follow up and discovered the approval was still not complete, got that taken care of then the glass was ordered and once the glass arrived the repair shop discovered the damage was more extensive and would require the entire sunroof mechanism to be replaced. They submitted a new claim to the insurance company; one estimate for 9K and then submitted a second one for over 12K bc they weren't sure of the amount.

The Insurance company decided to return the claim to State Farm at that point since it was more than just glass to be replaced. I had to return the car rental bc they had not figured out what to do. My daughter was without a car for a week and half. I continued to check on the claim and was told once it was approved, then I called to check on ETA of part and was told no it was not approved and that they stated it hadn't even been submitted, then was told by State Farm it was on hold due to the two estimates submitted. Then was informed the repair shop was not comfortable performing the work because it was so extensive. They thought I should take the car to a Ford dealership to let them provide an estimate because they thought Ford could get the part cheaper and this would eliminate the need for State Farm to total the car due to the cost of the repairs.

State Farm would not authorize this, they are currently requiring the repair shop to provide an accurate estimate before they will make a decision on whether we can take it to a dealership. In the meantime, they would not authorize a car rental and suggested this didn't meet qualifications for it to be extended. I had to plead my case with an agent who stated she would write up a proposal for a manager to review and it would be 2 business days before they would respond.

In the meantime, my daughter has to return to school so I have to pay out of pocket for a car rental. Enterprise quoted $170 per day. This has already been a month long process and if this takes another month (or longer as I anticipate based on them telling me the part is very limited) then it would cost me $5K to rent a car for a month until State Farm decides how to handle. Even if I take this to dealership I do not have an idea on their timeframe to even inspect or repair. This continues to be a drawn out process that is costing them money and very little assistance or concern from anyone involved. I am dreading the discussion with State Farm that they cannot total my car for 12K when this car is in great condition, was 38K to begin with and you cannot purchase a car in similar condition or mileage for anywhere close to that price.

One occupant in vehicle (driver) and German Shepherd dog (cargo area). Traveling on two lane highway in rural setting. Speed: 45 mph. Outside air temperature: 47 degrees F. Road conditions: smooth, dry, asphalt surface. No other traffic or pedestrians in immediate area. Loud explosion noise similar to a window being shot out. Looking upwards at sunroof: it was badly cracked and crumbling. Pieces of glass falling from car. Vehicle stopped and examined. No foreign object damage. No point of impact noted. Glass sunroof was badly cracked around entire perimeter. Many small pieces had blown off car. Vehicle slowly driven home and garaged.

This was obvious structural failure causing the perimeter breakage rather than at a single point of impact. On Monday, vehicle moved to local Ford dealer and presented to service manager. Photos were taken. Manager agreed it appeared to be glass failure and would contact Ford about repairs at their expense. Vehicle was driven back to residence at 20 mph due to glass continuing to break off at any speed higher. Ford service manager reported back on Wed. 20 Jan 16 and advised Ford will not pay for a replacement roof. He further stated he would take the complaint to the next level and report back as soon as an answer was obtained. A memo was sent to the manufacturer of the glass: Carlite Glass requesting any information on updated production formulas for replacement sunroofs. Another glass failure following this repair is not acceptable. A complaint was made to the National Highway Safety Admin. This problem is pending. This exploding sunroof problem is not uncommon and a complete recall is required before someone is seriously injured or killed. No matter what the outcome, this will be my very last sunroof option.