One of the rear hatch's struts came loose when opening the hatch. Upon closing, the strut was forced out the top of the hinge, causing damage to paint, trim, and the hatch panel itself. The strut was replaced on this trip, not the damage.
Issue: Rattle coming from the passenger side A-pillar. Repair: I removed the washer fluid bottle and used HVAC tape to tape down the washer lines that go up the A-pillar to the rear wiper. 5 minute repair.
Carpet on rear of rear seats fell off and needed to be re-glued.
Assess driver door misalignment. Dealer sent photos to Ford.
The mechanic tried to adjust a rear window trim panel that was improperly installed at the factory. It's still imperfect, but I think the whistle is gone.
Persistent body rattle, dealer unable to locate/repair.
Dealer unable to locate rattle, but acknowledged there is one. Second dealer to look at car, turned over to Ford customer service.
Carpet trim inside fell off the folding rear seats in the trunk/hatchback area. I guess they glued them back on. There was a service bulletin. I also took the car in for a recall.
Passenger door panel loose. Replaced door card
Paint defect reported to Ford. Photos taken. Waiting for approval to repair under warranty.
Brought in to complete the paint work, they had the car 17 days (scheduled for 3). Not completed successfully, and I will not be taking it back. DON'T BUY THE TRI-COAT METALLIC WHITE PAINT, it's a nightmare (and expensive) to repair.
Loose trim on handbrake and luggage area cargo tie-downs.
SIgnificant body flex causes the doors to creak almost continuously. The dealer claims to have repaired this by lubricating the door seals, but the problem is not resolved. The doors creak as much as before the repair visit.
Metal speaker cover on the top center of the dash rattles constantly because it's loose. Carpet in the cargo area separated from the plastic flaps that fold down when the rear seats are folded flat. The adhesive holding the carpet has separated from the plastic.
Carpet started to come off in the rear. The carpet is glued to the rear panels in some places, and the glue lost its bond to the plastic panels. Simple fix, just had to re-glue the carpet.
Dash board rattles
Door seal wasn't put in right when the car was built.
Power liftgate does not close all the way on its own.
Door handle tray was loose. Carpet peeled off from cargo area.
carpet needed to be reglued in the back storage area
Headliner showed water stains. Dealer sealed the windshield and roof seams, and replaced the headliner.
interior panel of the rear passenger door (door handle, etc) came apart from the external door panel. I think the plastic pins that hold them together broke. Dealer fixed it under original warranty, but it required two trips. carpet in the trunk lost its adhesion to the floor/back of seats. Dealer glued it back on under warranty.
rubber door seal was ripped and missing on driver's door