Wider washers may prevent cracking.... I've never had a problem with just snugging the bolts down... they do not need to be torqued hard to hold (I've had the jeep since Nov 07, I put it on to take road trips... about 3 times a year.

The Freedom Panels... I've read many times of people overtighting the long bolts that go through the sound bar and thus the bolt punctures the F top. On each F panel there is a flip down rest (right behind the the threads) that will allow the panel to ride on the cross member above the sound bar. When you put the bolt in you cannot overtighten and run it through the F panel.

 

I wonder if the front roof section speaker bar screws are keeping the forward part of the rear hard top under compression so reducing the load on them and acting as a sort of pivot point which is then in turn causing more pressure upward on the rear bolts. Mine also cracked 6000 miles , just contacted the dealer. Not happy .

Just been next door to the marine store and got some large Stainless washers to spread the load.

My front section also has a crack each side of the front handle. This has been caused by the lip of the edge of the screen being bent down, where the seal sits so the handle part of the roof was not supported in anyway. Basically the roof was being supported by its ends only at the front, whilst get pulling down in the middle by the handle.

I have not noticed the cracks on the rear section before, but we have just had spell of cold weather and wondered if this has caused the plastic to be more brittle.

I shall be taking it up with the dealer , I will tell you how I get on here in the U.K.

 

When I inspected it last night I noticed the other issue is not just the size of the washer but the rather large gap on the underside. The foam pad does not fit all the way round the screw hole. The inter part where it is cracking on all of them is unsupported there is a gap in the foam in that section of about 3/4'. So even if you put big washers on it its still a weak point.
I got some sticky foam pads of equal thickness to the OE foam and plugged the gap and then large stainless washer and hand tightened the bolt.
There is now no bow in the plastic and it is supported equally for the underside and spreading the load with the washer.

 

They are replacing mine under warranty! Next week

 

Good for you !! It appears you have a better zone rep than I had when trying to get mine replaced.

 

MMmm Jeep U.K said the bolts had been over tightened ( which is BS) and are not going to do anything about it .