polonius

The dealer attempted to trouble shoot multiple times over about 6 months and found the issues with the windshield and mirrors. They also figured out the evaporator case after I collected a lot of observational data when the "whistle" occurred (what speed, outside temperature, outside wind speed/direction, configuration of the A/C (cabin recirculate on/off, A/C on/off, MAX on/off, etc)) and after they spoke with an offsite Ford engineer. They did call in a specialist at one point ... that might be the same as the "roving field representative". One other piece of information that could be helpful: There was one other problem with my Edge; air was getting in between the door and the frame and escaping from the seal at the A pillar (at the top, by the driver's head). This fix was similar to the side mirror fix (adding foam) and was done at the same time.

In my case, the wind noise came from several sources: 1) The windshield was not fitted flush. The dealership actually had to order a replacement windshield. 2) The foam issue for the side mirrors as described in other posts. 3) The evaporator case was cracked. This was the last source of the 'whistle' wind noise (only at higher speeds and only with certain configurations of the A/C) and took months and several trips to the dealership to identify. Since the replacement of the evaporator case at the end of April, the cabin of my Edge is finally "quiet".

I have experienced the same driver side wind noise issues and have had those resolved (added foam at the mirror base and blocking airflow that was getting in between the driver door and the A pillar), but I am curious if anyone has had this additional problem. There is a whistle (sounds very much like the wind noise whistle) coming from the A/C vents at speeds higher than 45-50mph. The whistle stops when the fan is left ON, but the A/C is turned OFF. In all other combinations (cabin air recirculate, MAX, system (including fan) completely off) the whistle is present. There is no correlation with outside wind conditions (e.g. this happens on very windy days and very calm days) Ford has not (yet) been able to identify the issue. I suspect a baffle somewhere in the A/C system is not fully closing and the air moving across the gap is causing a whistle. This is a 2011 Edge SEL