I'm jumping in here as I hope someone from Ford is reading these customer concerns. I don't want to come across as jumping on the complaint band wagon but...I have purchased many new vehicles over the years and this is the worst job of quality control I've ever seen. No excuse for shoddy assembly! My dealer was great when I poinedt out all the gaps (hadn't seen the dents/dings yet) and said they would gladly take care of it under warranty...but who really wants to take a brand new vehicle into a body shop for what should have been done right on the assembly line?
My passenger side hood edge is 1/4" to 1/2" lower than the fender, front fascia gap is HUGE, and the rear bumper (passenger side) gap, so large you can see the tabs through the gap. Astonished it passed the final QC inspection at plant! Additionally, I had 4 dents/dings, one in the center of the hood and three on the trunk lid. I paid $160.00 this past Friday to have the dents/dings removed (I know a very good dent/ding removal guy - true craftsman). I removed the rear spoiler to remove the tape stripe where it ran under the spoiler and there were 4 sizable gouges down to bare metal...looked as if the spoiler had been dropped on the trunk lid during assembly. I did touch up the gouges before reinstalling.
Wile I realize everyone is going with thinner/lighter materials to save weight (better mileage) honestly this car feels "fragile"...for instance, my ding repair guy closed the trunk lid from the passenger side and due to the flex in the hinge assembly the trunk lid chipped the area under the rear window where it meets the front of the trunk lid...not his fault, as (IMO), the trunk/hinge assembly should be a bit sturdier than that...I urge you to close your trunk only from the middle and gently.
Having said that, I like this car, and do understand that all manufacturers are doing the same thing, but it feels as if Ford's QC process needs to be addressed...just my .02