ok, went up a hill today in D with the stereo off and the windows down, stayed within the 2500-3000 range for more than a few seconds and it's definitely the wastegate actuator rattle. I'd expect to hear this sort of noise from an old Excel with a valvetrain that's kept in time with zipties and blutac.
I can now understand why people are so pissed off. Unfortunately I don't think it will be fixed, the cost would be too high and the effect of not fixing it is probably next to nothing in terms of lost sales/disgruntled customers. That is shortsighted and pretty poor. Ford lost me by denying a single $500 warranty claim, and I'll probably never go back.
The rattle and the popstick sun visors are really the only negatives I can pick from this car, otherwise it's pretty awesome.
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