I hope it's not a terrible breach of etiquette to reply to this thread so long after the last post, but I just recently got a FE Cliffjumper at TRU and had the exact same problem. That whole grille chunk just snapped right off. Shoddy design plus fairly typical vague instruction sheets are to blame, as I seriously thought there was possibly another hinge there that was supposed to fold a little more. I gave a little too much force apparently, not worrying as most toys in the last 15 years or so have had parts pop off when you do this without doing any permanent damage, but no, that stupid metal rod that didn't need to be there at all made the hinges crack open. Then when I attempted to turn him back into a car those hinge parts came completely off. So, is there any good fix for this? I'm thinking of trying crazy glue, but am not sure if I have the manual dexterity to get the glue and hinge pieces into such a tiny spot so before trying this would like to know if anyone else has had luck with such a repair (or has a better option). I would return the toy if I thought I could find another, but I've only ever seen one on shelves, and honestly would rather have it broken than not at all.