Welcome to the forum!
I think you have probably had a bad experience, to be honest, you will get this with most cars. Something, somewhere will go wrong, its just a case of how much to fix it!
- New bonnet catch cable - This is a problem with most Ford's, they appear to have gone for budget before quality on these!
- New Drivers seat belt catch (fasten seat belt alarm continuously going off for 300 miles on holiday!) - passenger side looks like its
starting to do it too. - that would irritate the life out of me! I dont know how expensive they are but you may be able to replace it yourself and buy a unit off ebay or if you find a bodywork write off in the scrappies just getting one from them!
- Drivers key fob remote doesn't work, unless I use my wife's first then its fine! (apparently its "wearing out". Its electronic not
mechanical! And £100 quid for a key remote? REALLY!?!?) - I suspect the issue here is that the switch under the button is not making a contact correctly. is it a flip key with a flat blade, or tibble blade? you could pick up a new remote off ebay for a few quid, and then swap the immobilisers chip over, along with the blade. Let me know which type you have and I will see what I can find for you!
- 2 tire valves literally falling out (one of which on outside lane of motorway with said kids, dog and camping gear in -
not nice experience). The remaining 2 have also now all but disintegrated (at a nice £140 each too). Although I since discovered
that you can replace the valve WITHOUT having to replace the whole sensor unit - of course Ford didn't give that as an option!). - Unfortunately it seems that Ford did take the mick on this instance, it sounds like yours might have been part of a defective batch, however I would suggest buy yourself two new valves, take the car to an independent Tyre fitter, and ask them to change the valves for you. It may cost you about £20 - £30 all in, unless they want to check balance etc.
- There's lots of other little things too like all the enamel falling off the rear badge (seen LOADS with similar problem). - This is a bit of a design flaw in the badge, however, there is an easy, cheap and better looking fix! google "DMB Gel Overlays" and invest in a set. It sticks on, bonds with heat (hairdryer) and you can get your own style, colour combination, and they are much better wear and tear wise.
- Keep finding various bits of plastic inside that have fallen off from "somewhere". - Was this car new when you bought it, or used? it could be a careless fore-owner, otherwise it could be that it hasn't been as well built as others.
As for the tyres, I suppose the weight of the car is its own worst enemy this way, if you get a car of a similar size then you will probably see the same problem. What mich's do you go for? if you go for a hard wearing compound, they should see you right for a bit longer... How many miles do the tyres last on average / how many years?
As for the exhaust, what was the issue? was it just as simple as a rusted clamp, or was the exhaust unit itself rusted through? you could get a much cheaper exhaust than that, and one at a better quality... you got a much better deal with the aftermarket one though!
With regards the MOT, remember, you don't need to pay Fords to fix it! When you collect the car, find out what went wrong. Ford cannot stop you from driving away. Before you go to collect the car, speak to a friend or the Mrs, and tell her if she gets a weird call, to just roll with it. If Ford insist that they cannot allow you to drive the vehicle, phone said friend, and introduce yourself as if you are having a call with a garage (treat the call as if your best mate owns a garage and you need the repairs done!) tell them the issues and play along like you are getting a quote and arranging repair. "What was that, bring it down now and you will have a look at it? no problem, will do!". Tell Ford that you have arranged a repair with a garage, and that you are driving the vehicle to them to have it repaired. (see this site, your allowed to drive the vehicle, without a valid MOT if you are going for repair!).
Now if you drive the car home, technically you are driving your car illegally, and we do not condone it. However, if it was to be driven home, and you promise that you are going to arrange the repairs with another garage (or repair the vehicle yourself).
Now, because you have taken the car from the garage, you could go back within 10 working days and have a "partial retest" this would not be the full MOT fee, but a partial fee, and so would be slightly cheaper. Any time exceeding 10 working days, you would need to pay for a full MOT. You also have the option to have the vehicle MOT'd at another site.
Now, how you proceed is your choice, I am not advising you to drive illegally and without an MOT, however if Ford are going to charge you a bomb, there is nothing stopping you taking your car to repair at an alternate site in order for it to pass the MOT...
Hope this is of some help