Here there - appreciate everyone's attempt to help. That is why I joined in - listening and learning! It is frustrating when you can not dupicate the problem, both for the dealership and the owner.
As far as the control arm,I am just going by what I was told by the dealership(s) and is on their repair information. As I understand it, the metal control arms were crimped too tightly in the manufacturing process causing them to leak. I will agree, I am far from technical when it comes to autos so am relying on what I am being told by the 2 dealerships that have worked on this problem. Shortly after this was originally diagnosed, Ford acknowledge the problem with many other vehicles but they didn't have a replacement part for almost a year. Therefore, we went through one additional replacement before the new part was finally available.
And as far as the question if we bought it new or used; it was purchased new. Yes, we programmed our vehicle recognize two different drivers (and have been made aware of the error in the owners manual so have the new instructions). Why could this be part of the problem? That is what this option is for. Worked perfectly in our previous Lincoln. They have replaced the key fabs, a module but thus far, no solutions to the problems. Again, I understand the frustration of the dealership and they recognize our frustration as well. But that pretty much leaves us at an impasse until someone figures this out! I have offered to leave the vehicle for a month as long as I am supplies with a "like vehicle" but this is the problem. They don't have "like vehicles" for loaner cars as Lexus or other higher end dealerships do.