Ask yourself this. If you were looking to buy this car from a dealership or private party and it made the noises you describe, would you still be interested in buying? Or would you think the noises significantly affect the asking price? If Ford can't fix the problem, eventually you will be faced with these questions. Your trade-in value will be affected. I suggest looking into your state's lemon laws to see if this qualifies. You can always do a search and speak to a lemon law attorney free of charge to see what they can suggest.
Do you have in writing from the dealership that they acknowledge the noises do exist? If not, get them to, without that you don't have a case.
