Well, I took the car in for a second time, told them to keep it long enough to solve the problem. They had it for three days and gave up. They literally took the front end apart, to include body parts and didn't find a thing. They agree the noise is there but they can't find it. I've got the car back now pending dealer tech consultation with Ford. If there is no resolution the dealer is willing to pursue a buyback.
I spend a couple of hours discussing my options with the dealer, but I don't see a way out of this short of ignoring the noise. I don't want to give up the horsepower, the cargo space and the size of the Explorer. Expedition, too big, F150 too big, Edge, too small, and I don't want to buy back into a 2019, even if I could find something.
All I can say at this point is that I'm extremely disappointed in my choice and blame myself for not spending more time on the Forum before making a decision. I think I would have delayed my purchase to a later date after Ford cleaned up its act.