I want to close the loop on this for anyone else who has a similar problem b/c it is frustrating.
A new starter has fixed my issue.
Importantly the dealer tested my starter solenoid voltage drop and it tested ok so they said the starter was fine. After much to do I got them to say the v-drop was bad so Ford would replace the starter under warranty. Thankfully they did this for me and my problem has been solved.
So just because the dealer says the starter is good dont mean it is !!
Good luck to anyone else who runs into this issue.