I have expereince with two buy-backs.
Immediately file a Dispute Settlement Form. Nevada's Lemon Law is only applicable to the first year of ownership.
First, stop giving Ford chances. Stop talking with Ford Customer Service (except to request the Dispute Settlement Form). Sever related ties with your dealership (after you ask for all history and paperwork of your repairs - don't tell them it's for a DSB case). They will all string you out with promises and excuses until it's too late. Believe me.
Immediately call Ford Customer Service and specifically ask that a Dispute Settlement Form be sent to you. Tell them you expect to receive it in the mail within 3 days. In the mean time, send a short certified letter to Ford Customer Service stating your case. Spare the details. Include copies of your records and a demand for a full refund or new replacement vehcile.
If you have not received a Dispute Settlement Board arbitration package from Ford Customer Assistance Center, write to the Dispute Settlement Board, PO Box 5120, Southfield MI 48086-5120, and explain that Ford has not given you one. They will supply you with what you need.
Get the form submitted, and get your case rolling as soon as possible. Your records are important. Keep cool and professional...the Dispute Board are not Ford employees, they are unpaid volunteers who are there to help you...Consumer advocates, so to speak. During the process, take every opportunity to dispute what Ford is going to say. Take advantage of speaking with the Board, not to vent, but to professionally make your case.
If you do not agree with the Board's decision, you can still pursue it legally. I don't know what the BBB can do for you.
Again, don't settle for more chances to repair. And don't settle for an unreasonable usage (mileage) charge.
Good luck. If your records are good you will win hands down. I won both of my cases, no questions asked.