Wow, leave for a few weeks and come back to 6 pages of comments. To everyone who has similar issues, my attempts to use this entire near 5 month ordeal to pinpoint the issue and help the community has failed. Ford is incompetent in every realm of technical service and customer follow up.
Update: Dealer verified the same noise is back and is the same noise that led to engine replacement #1 from a Ford Engineer.
Corporate called me a day after the dealer verified and gave me the almost carbon copy corporate script. They're not willing to even attempt to get me out of this vehicle. They are only willing to continuously tear my car apart while the dealer service record racks up records on a future vehicle report and I already have to explain why the odometer doesn't match the engine. Lady swore up and down if for sure have a call back with an update about what Ford was going to do by Wednesday. No call as of today.
I got printouts of all my service trips and have kept every voicemail from Ford and the dealer. If Ford tells me to pound sand again legal action is coming.
FORD CORPORATE IS CRIMINALLY PATHETIC. I know another guy going through total hell right now with a loaded Ford vehicle, brand new. I heard one of the voicemails he got from Ford, SAME LADY, SAME script. Ford doesn't care dick about their customers or each situation. They just want you to go away quietly while you continue to get fisted. Heard it right from the dealers mouth, they said "when it comes to corporate they are clueless with working with their own dealers. The left hand doesn't know what the right is doing."
And please Ford Service who's on these boards, feel free to pass it on that I'm going to continue to give Ford all the "free advertising" I possibly can.