Pretty much as soon as we bought the car, we noticed a "reed-like" buzzing sound coming from the windshield area at highway speeds. It would usually only happen when you were driving through a crosswind. See the attached video for an example. Not my video btw.

I tried mentioning it several times at the dealer when I was in for service, but was repeatedly shot down as they couldn't replicate the issue.

It wasn't until I did some research and finally found a TSB for the issue that they agreed to attempt a repair under warranty.

The problem is the rubber "Cowl" at the bottom of the windshield. The factory one was very soft rubber and was easily flexed. The replacement is not.

See the TSB here for more info http://www.explorerforum.com/forums/showpost.php?p=3356848&postcount=306

An annoying and persistent high pitch whistle is audible above 60mph under most conditions. All windows are closed during operation. Dozens of chat rooms indicate that this is a known issue with a gap at the passenger side windshield cowling with the new model Ford Explorer. We are taking our vehicle into the dealership for service and will report if the problem persists.

Important to note that in some conditions above 60mph the noise can be reduced somewhat by engaging the air cabin recirculate button.

This is a significant design or assembly issue for a vehicle at this price point.