There are so many threads regarding this topic I didnt know which to reply to. Let me start by saying I am a member of the "crack club" my wife's 2003 with 89k miles has two separate cracks. I lived with the first one for over a year now but with the second I decided to take on the project. I was quoted between 400-450 by a few local body shops, So i ordered the part ($130) and am having it sprayed by a shop ($50) and will install it myself for about $200 total.
With that said, I take a ton of pride in my vehicles and maintain them meticulously, some say to a fault. I was disappointed to see the initial crack but was not overly surprised as i knew this was a common occurance. However, i've learned that there are much more important things to get bent out of shape about. Our 2003 is pushing 9 years of service - with 89k miles we've done only routine wear item repairs. If you were lucky/unlucky enough to have it crack during your 3/36 bumper to bumper then by all means you are entitled to a free repair. I can't see getting so worked up over a piece of trim cracking on 6,7,8,9,10 year old vehicles. Yeah it SUCKS and is a known problem but name me a car that doesnt have inherit flaws that crop up over years of sales and service.
My 2003 has been reliable, safe and still looks pretty good for its age, I made the decision to repair the crack on a budget, to keep it looking good, If there comes a time that a design flaw puts my family in any danger i'll be the first to spearhead a resolution campaign. If you don't plan to buy another ford because of this flaw, then don't, but the grass isn't any greener on the other side. There are plenty of good car companies out there to choose from, and each have their own +/-.
for those interested in doing the project themselves the part was purchased from fordpartsgiant.com part # 1L2Z-78402A30-CAPTM and was $124.01 + shipping. A local body shop is spraying it for me for $50 (which is cheaper than i could have done after purchasing paint and supplies).
I hope you all find the resolution you are looking for, but remember, if you put things in perspective, this probably won't rate too high on the list.