Thanks for the number Tez
I'm quite surprised that the Ford CR department was quite efficient and seem willing to help! I was expectiving to get fobbed off by some Indian call center but actually they seem quite good. Hopefully they will contribute something towards the cost of the rack but I should find out monday if they do. I've still got to stump up the full amount today because PolarFord won't let me take the car without paying it all. I've got to have a photocopy of my service book faxed to Ford before they agree whether or not to help out with the payment.
If anyone else is thinking about making an out of warranty claim in the future, Ford have a cut-off point of 45 months from the car being new. Also the car must have a full service history, preferably at a Ford dealer (you'll have more chance of a higher discount and them doing something about it). Of course you can still take them to court under the sale of goods act which many people don't know about -
For up to six years after purchase (five years from discovery in Scotland) purchasers can demand damages (which a court would equate to the cost of a repair or replacement).
but...
After six months and until the end of the six years, it is for the consumer to prove the lack of conformity.