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Ok, I had it with Ford and their dealership. I went back for the second time and they basically gave me the run around. It seems like there really is no true solution to fix this piece from popping out. I tried popping it back in and the more I try to fix the problem the worse it gets. Is ther any way we can start some sort of a recall/TSB since it seems like I am not alone...
Yes, what you are having trouble with is an aggravation. My cowl also has the same problem. Well it did until I fixed it. All I did was make sure the small tabs near the center of the cowl located in the drip edge or "gutter" (where the two pieces meet in the center of the truck under where the back of the hood would be if it were closed) are holding the passenger side cowl piece in place. I have to admit it was a suprisingly delicate operation for a truck and is a poorly designed setup. Once I got the thing in place I have not even thought about touching it for fear it will pop loose again. It has been in place now for about 4 weeks.
Good luck, and I know how you feel about ford service. I have to drive to a neighboring town to get good service because the dealership in my city refuses to service my truck because I did not buy it at their dealership.
I tried lining up the "tabs" and it just wont click in or stay together. I was thinking of drilling a small hole from one cowl to another, on that tab, and sticking a bolt and screw to keep it tight.....OR even zip ties
Wrong tabs. Look in the drip edge in front of the cowl behind the rubber hood seal. Heck, take the hood seal off if it helps. The tabs are about 1/4" by 1/8" or so and there are a total of 6 on my truck that the front edge of the cowl pops under. forget about the "locking mechanism in the center, you'll never get that stupid thing to snap together. I know, because I fooled around with the darn thing for about 3 hours one afternoon. This may require you to climb up into he engine bay to see what I am talking about. Hope this helped.
Just got back from the dealership. This dealership, different than the first dealership that replaced the cow, called up Detroit and found out that the fix was to remove the insulation for the cowl. I also mentioned applying silicone and he said it wouldnt be a bad idea. I just went out and bought some clear silicone and going to apply it as soon as it stops raining.
I had my cowl replaced under warranty for the same thing. I haven't had a problem since. I am more careful when I wash the truck to not allow it to slide in either direction. Good luck!