I also had the same issue. Through trial and error, I found that it was related to the memory function being tied to one or both key fobs. I unlinked all my key fobs from the memory function and I've never had the issue since.
Changed the oil 4 times on my truck and have always used the same clips without stripping either the bolts or clips (hand start first, then use a clicker wrench or impact). Not sure what you mean by non-reusable.
Engaging 4A/4H from 2H can be done at any speed as long as the accelerator pedal is not pressed and/or rear wheels are not slipping. Engaging to 4L requires the vehicle to be under 3 MPH and placed in neutral.
More info beginning with page 16 in the supplement manual.
That's a hydrocarbon trap for emissions after key off. Will not affect anything.
I believe that it was mid-calendar year change so I would say mid-2019. Don't know the exact cutoff date. New turbos came with all 2019+ and then the vanes got deleted later on.
There should not be any swirl vanes on MY2019+. The turbo compressor inlet was switched to a ported shroud design in 2018 that eliminated some of the turbo whoosh noise and improved the pre-turbo swirl ratio.
For the Raptors/Tremors that are most recently built (~ April 2022), the air deflector in front of the air inlet has an updated opening to allow more air flow. Additionally, christmas tree clips with "firs" have been eliminated and have been updated to the 2 piece push in style rivets as Gen 2...
I would look at an Expedition Max (with the extended wheelbase). Plenty of room in the trunk and comfortable seating for 7. If you get the Timberline package, it has the same 3.5L HO engine as the Raptor (with slightly less HP; ~440HP).