Heard back from the dealer today. My service guy called me in and took me directly to the GMs office. The GM told me they fixed the issue. I was hesitant to believe him. So we go for a test drive and I'm ******* blown away!!!! It's gone!!!
He says the owner of the dealership owns a raptor with a curved bar just like mine and had the same issue so he had a guy work on his personal raptor non stop until the issue was found. Turns out it's not an electrical issue.
The wind going over a CURVED bar at a certain speed create a "tuning fork" affect. With a straight bar, all the wind comes from the front and shoots straight back. With a curved bar, wind comes at the bar from several directions and all meets upon the rear of the light bar, causing excessive vibration, leading to a tuning fork affect.
The GM got some green painters tape and taped down all the fins in the bar of my curved bar, we got in and drove at all speeds and wouldn't you know....NOTHING!!!!
The GM says that because of their proximity to the desert, they routinely work on fixed up trucks and have learned a lot of tricks of the trade!!!
They're still working on my rear passenger door lock and front passenger seat but after seeing this, I'm a believer. They could've said "this is an aftermarket part causing the issue sober aren't gonna help you". But they really stepped up to make a customer happy.
+1 for Fiesta Ford of Indio, Ca and their attentive staff.
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