I have the same problem and did the BCMB thing but it didn't fix it. I am just past 36k miles but have a 5yr 75k premium warranty. Guess what isn't covered in that warranty? The head and tail lights.
If Ford tried to fix it under warranty and you are still having the problem, seems like they were not successful in the repair. I would point that out to the dealership and ask what Fords procedure for warranty repairs that were not properly corrected.