My name is ***** ***** I will assist you with your question today.
I'm an independent contractor and I don't get paid until a rating has been made.
We can go back and forth as needed to help resolve the issue you are having. Follow ups are free after ratings, so rate in confidence!
In regards ***** ***** lemon law, I would speak to an attorney in regards ***** ***** There are many rules in how that is enforced with a lot of criteria.
On the issue, did Ford mention at all about the 4x4 module being changed and/or te harness inspected? You should have a ESOF aka Electronic Shift on the Fly setup in this truck meaning it can shift to 4x4 while driving, but you shouldn't have any sound at all when it happens. Like you, I am concerned with the noise that you heard that you have some damage to the system somewhere. Getting grinding noise is a good indicator of transfer case damage or front axle damage, However, I can't confirm anything like this until I pull it apart and inspect it.
I suggest if going the legal route, to contact an attorney and then have them send you to a shop that specializes in failure diagnosis to inspect the vehicle. They will send the fluids in to a lab which will be tested for the various metal fragments which will be a huge plus for you to do.
There is definitely something going on with the whining noise and yes, there is most likely some sort of damage because of it.
You want a 5 star service and I want to provide a 5 star service. Please consider that I don't know your skill level as well as I can't see, touch, smell, hear the vehicle/machine in question. Please provide as much detail as possible and I will provide as much back.
Once an answer is provided, you should see a rating screen. Please rate my personal service to you. The ratings are my personal feedback, they are not the site feedback.
Thank you for allowing me to assist you through Just Answer!