A lot of common stuff going on here with builds of 2017 Expy's. My front passenger door was out of alignment and stuck out at the bottom to a small extent. Dealer was able to adjust the hinges and get it pretty close to - if not perfectly - aligned. I am good with it. My truck also has the commonly misaligned rear lift gate discussed here in another thread. I chose not to have it adjusted for now as it requires dropping the headliner. No leaks or rattles currently, so I am likely to leave it all alone or have it addressed before the warranty expires.
I also had to have the top windshield trim replaced as it was coming unglued on one side near the roof channel. Dealer wanted to pull the entire windshield to "do it right". Instead I took it to a local auto glass shop and they re-glued it in place in about 15 minutes for free.
Very curious to see and drive the new model this Fall. It seems Ford has issues with fit-finish Q/A on the assembly line.
I ordered and bought a new 2015 Expedition Limited 4x4. I picked it up two days after it was delivered to the dealer - with two miles on it.
The LF wheel opening molding was loose and not fitted correctly. The black plastic nails on the inside of the wheel opening were not seated and installed crooked. The painted mounding at the bottom of the LF fender, behind the wheel, was also installed crooked. It was very obvious when you walked up to the vehicle. I had to return it to the service department for repair.
The right side of the hood, at the rear by the cowl, was lower than the top of the RF fender (about the thickness of two quarters stacked). I removed the bolts on the right hood hinge (the ones that hold the hood) and added two shims to raise the hood. Now, the hood is flush with the fender (when the hood is closed).
This was my first Ford and I was VERY disappointed with the poor fit and finish. Both problems were very easy to see. A line worker didn't do his job, the quality control inspector didn't do his job, the dealer service tech (who was paid to inspect and prepare the vehicle) - didn't do his job, and the salesman overlooked the problems. In retrospect, I should have refused the vehicle. I did note that the condition of the vehicle was "much worse than expected" on the survey from Ford. It was obvious that Ford does NOT care about problems with their new vehicles.